Golf ball

ABSTRACT

The present invention is directed to a solid, non-wound, golf ball comprising two or more core components, and a cover component. The core components comprise i) a small, inner, high density, spherical center component comprising a blend of powdered metal and a first matrix material selecting from the group consisting of a polybutadiene, a polyisoprene, or combinations thereof; and, ii) an outer core layer disposed about the spherical center component, formed from a second matrix material selected from the group consisting of a thermoset material, a thermoplastic material, or combinations thereof. The golf ball may further comprise a second or additional outer core layer(s) that surround the first outer core layer. The cover may be single or multi-layered. For a multi-layered cover, the inner cover layer is comprised of a low or high acid ionomer or ionomer blend and the outer cover layer is comprised of a soft, very low modulus ionomer or ionomer blend, or a non-ionomeric thermoplastic elastomer such as polyurethane, polyester or polyetheramide. The resulting golf ball of the present invention provides for enhanced playability characteristics (i.e., spin and feel) without sacrificing distance or durability properties.

CROSS REFERENCES TO RELATED APPLICATIONS

[0001] This application is a continuation of U.S. Ser. No. 09/726,742,filed Nov. 30, 2000, which is a continuation-in-part application of U.S.patent application Ser. No. 09/394,829, filed on Sep. 13, 1999, now U.S.Pat. No. 6,277,034. That application is a continuation-in-part of U.S.patent application Ser. No. 08/870,585, filed Jun. 6, 1997, nowabandoned, which is a continuation-in-part of U.S. patent applicationSer. No. 08/556,237, filed Nov. 9, 1995, now abandoned, which is acontinuation-in-part of U.S. patent application Ser. No. 08/070,510filed Jun. 1, 1993, now abandoned. Application Ser. No. 09/726,742 isalso a continuation-in-part application of U.S. patent application Ser.No. 08/840,392, filed Apr. 29, 1997, now issued as U.S. Pat. No.5,779,562, which is a continuation-in-part of U.S. patent applicationSer. No. 08/631,613, filed Apr. 10, 1996, which in turn is acontinuation-in-part of U.S. patent application Ser. No. 08/591,046,filed on Jan. 25, 1996, and U.S. patent application Ser. No. 08/542,793,filed on Oct. 13, 1995, which in turn is a continuation-in-part of U.S.patent application Ser. No. 08/070,510, filed on Jun. 1, 1993.Application Ser. No. 09/726,742 also claims priority to U.S. ProvisionalApplication Serial No. 60/171,701, filed Dec. 22, 1999.

FIELD OF THE INVENTION

[0002] The present invention relates to golf balls and specifically tothe construction of solid, non-wound, golf balls for regulation play.More particularly, the invention is directed to improved golf ballscomprising multiple core assemblies which have a comparatively small,high density, polymeric center, or nucleus, component. The small, heavycenter component in combination with the particular remaining core andvery thin cover components produces a golf ball having a smaller momentof inertia about its central axis. This results in a golf ball whichexhibits enhanced spin while maintaining or improving additional golfball characteristics such as durability, resiliency and compression.

[0003] Furthermore, the small, heavy weight, polymeric center componentof the invention is preferably produced without the use of one or moreperoxide crosslinking, or co-crosslinking agents comprising a metal saltof an unsaturated fatty or carboxylic acid. These crosslinking agents orcoagents are the reaction product of an unsaturated carboxylic acid oracids and an oxide or carbonate of a metal such as zinc. Examples ofsuch crosslinking agents, which again are preferably not incorporatedinto the present inventions, or if so, only to a minimal amount, includezinc diacrylate and zinc dimethacrylate. Accordingly, the polymericcenters of the golf balls of the present invention are generally freefrom peroxide crosslinking agents and exhibit high densities.

[0004] Additionally, in a more preferred aspect, the small, heavy centercomponent of the invention is produced through the use of a blend ofpolybutadiene and polyisoprene rubbers. Powdered metal materials andother materials, including curing agents, may be incorporated therein toproduce a high density, spherical center component that is commerciallyprocessible.

[0005] Moreover, in a particularly preferred aspect, the balls of theinvention further utilize a multi-layer cover assembly. The inner andouter cover layers are very thin (i.e., about 0.055 inches or less) inthickness. The improved multi-layer cover golf balls provide enhanceddistance and durability properties over single layer cover golf ballswhile at the same time offering enhanced “feel” and spin characteristicsgenerally associated with soft balata and balata-like covers of theprior art.

BACKGROUND OF THE INVENTION

[0006] Golf balls traditionally have been categorized in three differentgroups, namely, as one piece balls, multi-piece solid (two or morepieces) balls, and wound (three piece) balls. The one piece balltypically is formed from a solid mass of moldable material which hasbeen cured to develop the necessary degree of hardness. It possesses nosignificant difference in composition between the interior and exteriorof the ball. These balls do not have an enclosing cover. One piece ballsare described, for example, in U.S. Pat. No. 3,313,545; U.S. Pat. No.3,373,123; and, U.S. Pat. No. 3,384,612.

[0007] The wound ball is frequently referred to as a three piece ballsince it is made with a vulcanized rubber thread wound under tensionaround a solid or semisolid center to form a wound core and thereafterenclosed in a single or multilayer covering of tough protectivematerial. For many years the wound ball satisfied the standards of theU.S.G.A. and was desired by many skilled, low handicap golfers.

[0008] The three piece wound ball typically has a balata cover which isrelatively soft and flexible. Upon impact, it compresses against thesurface of the club producing high spin. Consequently, the soft andflexible balata covers along with the wound cores provide an experiencedgolfer with the ability to apply a spin to control the ball in flight inorder to produce a draw or a fade or a backspin which causes the ball to“bite” or stop abruptly on contact with the green. Moreover, the balatacover produces a soft “feel” to the low handicap player. Suchplayability properties of workability, feel, etc. are particularlyimportant in short iron play with low swing speeds and are exploitedsignificantly by high skilled players.

[0009] However, a three piece wound ball also has several disadvantages.For example, a wound ball is relatively difficult to manufacture due tothe number of production steps required and the careful control whichmust be exercised in each stage of manufacture to achieve suitableroundness, velocity, rebound, “click”, “feel”, and the like.

[0010] Additionally, a soft wound (three piece) ball is not well suitedfor use by the less skilled and/or high handicap golfer who cannotintentionally control the spin of the ball. For example, theunintentional application of side spin by a less skilled golfer produceshooking or slicing. The side spin reduces the golfer's control over theball as well as reducing travel distance.

[0011] Similarly, despite all the benefits of balata, balata coveredballs are easily cut and/or damaged if mishit. Consequently, golf ballsproduced with balata or balata containing cover compositions, canexhibit a relatively short life spans. As a result of this negativeproperty, balata and its synthetic substitute, transpolyisoprene, andresin blends, have been essentially replaced as the cover materials ofchoice by golf ball manufacturers by materials comprising ionomericresins and other elastomers such as polyurethanes.

[0012] Conventional multi-piece solid golf balls, on the other hand,include a solid resilient core having single or multiple cover layersemploying different types of material molded on the core. The one piecegolf ball and the solid core for a multi-piece solid (nonwound) ballfrequently are formed from a combination of materials such aspolybutadiene and other rubbers cross linked with zinc diacrylate orzinc dimethacrylate, and containing fillers and curing agents which aremolded under high pressure and temperature to provide a ball of suitablehardness and resilience. For multi-piece nonwound golf balls, the covertypically contains a substantial quantity of ionomeric resins thatimpart toughness and cut resistance to the covers.

[0013] Ionomeric resins are generally ionic copolymers of an olefin,such as ethylene, and a metal salt of an unsaturated carboxylic acid,such as acrylic acid, methacrylic acid or maleic acid. Metal ions, suchas sodium or zinc, are used to neutralize some portion of the acidicgroup in the copolymer, resulting in a thermoplastic elastomerexhibiting enhanced properties, such as durability, for golf ball coverconstruction. However, some of the advantages gained in increaseddurability have been offset to some degree by decreases in playability.This is because, although the ionomeric resins are very durable, theyalso tend to be quite hard when utilized for golf ball coverconstruction and thus lack the degree of softness required to impart thespin necessary to control the ball in flight. Since most ionomericresins are harder than balata, the ionomeric resin covers do notcompress as much against the face of the club upon impact, therebyproducing less spin. In addition, the harder and more durable ionicresins lack the “feel” characteristic associated with the softer balatarelated covers.

[0014] As a result, while there are currently more than fifty (50)commercial grades of ionomers available, both from DuPont and Exxon,with a wide range of properties which vary according to the type andamount of metal ions, molecular weight, composition of the base resin(i.e. relative content of ethylene and methacrylic and/or acrylic acidgroups) and additive ingredients, such as reinforcement agents, etc., agreat deal of research continues in order to develop golf ball covercompositions exhibiting not only the improved impact resistance andcarrying distance properties produced by the “hard” ionomeric resins,but also the playability (i.e. “spin”, “feel”, etc.) characteristicspreviously associated with the “soft” balata covers, properties whichare still desired by the more skilled golfer.

[0015] Moreover, a number of multi-piece solid balls have also beenproduced to address the various needs of the golfing populations. Thedifferent types of material used to formulate the core(s), cover(s),etc. of these balls dramatically alter the balls' overallcharacteristics.

[0016] In this regard, various structures have been suggested usingmultilayer cores and single layer covers wherein the core layers havedifferent physical characteristics. For example, U.S. Pat. Nos.4,714,253; 4,863,167 and 5,184,828 relate to three piece solid golfballs having improved rebound characteristics in order to increaseflight distance. The '253 patent is directed towards differences in thehardness of the layers. The '167 patent relates to a golf ball having acenter portion and an outer layer having a high specific gravity.Preferably, the outer layer is harder than the center portion. The '828patent suggests that the maximum hardness must be located at theinterface between the core and the mantle, and the hardness must thendecrease both inwardly and outwardly.

[0017] Similarly, a number of patents for multi-piece solid ballssuggest improving the spin and feel by manipulating the coreconstruction. For example, U.S. Pat. No. 4,625,964 relates to a solidgolf ball having a core diameter not more than 32 mm, and an outer layerhaving a specific gravity lower than that of the core. In U.S. Pat. No.4,650,193, it is suggested that a curable core elastomer be treated witha cure altering agent to soften an outer layer of the core. U.S. Pat.No. 5,002,281 is directed towards a three piece solid golf ball whichhas an inner core having a gravity greater than 1.0, but less than orequal to that of the outer shell which must be less than 1.3. U.S. Pat.Nos. 4,848,707 and 5,072,944 disclose three-piece solid golf ballshaving center and outer layers of different hardness. Other examples ofsuch dual layer cores can be found in, but are not limited to, thefollowings patents: U.S. Pat. No. 4,781,383; U.S. Pat. No. 4,858,924;U.S. Pat. No. 5,002,281; U.S. Pat. No. 5,048,838; U.S. Pat. No.5,104,126; U.S. Pat. No. 5,273,286; U.S. Pat. No. 5,482,285 and U.S.Pat. No. 5,490,674. It is believed that all of these patents aredirected to balls with single cover layers.

[0018] Multilayer covers containing one or more ionomeric resins havealso been formulated in an attempt to produce a golf ball having theoverall distance, playability and durability characteristics desired.This was addressed in U.S. Pat. No. 4,431,193, where a multi-layeredgolf ball cover is described as having been produced by initiallymolding a first cover layer on a spherical core and then adding a secondcover layer. The first or inner layer is comprised of a hard, highflexural modulus resinous material to provide a gain in coefficient ofrestitution while the outer layer is a comparatively soft, low flexuralmodulus resinous material to provide spin and control. The increase inthe coefficient of restitution provides a ball which serves to attain orapproach the maximum initial velocity limit of 255 feet per second, asprovided by the United States Golf Association (U.S.G.A.) rules. Therelatively soft, low flexural modulus outer layer provides for anadvantageous “feel” and playing characteristics of a balata covered golfball.

[0019] In various attempts to produce a durable, high spin ionomericgolf ball, the golfing industry has also blended the hard ionomer resinswith a number of softer ionomer resins. U.S. Pat. Nos. 4,884,814 and5,120,791 are directed to cover compositions containing blends of hardand soft ionomeric resins. The hard copolymers typically are made froman olefin and an unsaturated carboxylic acid. The soft copolymers aregenerally made from an olefin, an unsaturated carboxylic acid and anacrylate ester. It has been found that golf ball covers formed fromhard-soft ionomer blends tend to become scuffed more readily than coversmade of hard ionomer alone.

[0020] Most professional golfers and good amateur golfers desire a golfball that provides good distance when hit off a driver, control andstopping ability on full iron shots, and high spin for short “touch andfeel” shots. Many conventional two piece and thread wound performancegolf balls have undesirable high spin rates on full shots. The excessivespin on full shots is a sacrifice made in order to achieve more spin onthe shorter touch shots. Consequently, it would be desirable to producea multi-piece golf ball that exhibited low spin on full iron and woodshots and high spin in the “touch” and “feel” shots which occur with thehigh lofted irons and wedges around the green.

[0021] In this regard, the multi-piece nonwound balls, while having anadvantage with respect to cut resistance, typically have a cover that issufficiently hard so as to provide low deformation upon impact and asmall contact area between the ball and the club face. This provides agreater degree of “slipperiness” on the club face and, therefore, lesscontrol over the ball and greater difficulty in stopping the ball on thegreen when using short irons. At least some of these deficiencies areconsidered to result also from a large moment of inertia exhibited bythe multi-piece balls. Thus, it would be useful to develop a ball with acontrolled moment of inertia coupled with a soft cover layer in order toprovide the desired backspin when using short irons, but at the sametime without adversely impacting the desired flight and roll distance ofthe ball when using a driver.

[0022] A dual core, dual cover ball is described in U.S. Pat. No.4,919,434. However, the patent emphasizes the hardness characteristicsof all layers, particularly the requirement for a soft inner cover layerand a hard outer cover layer. With respect to the core, it requires thatthe layers should not differ in hardness by more than 10 percent andshould be elastomeric materials having a specific deformation rangeunder a constant load.

[0023] U.S. Pat. No. 5,104,126 attempts to concentrate the weight of thegolf ball in the center core region by utilizing a metal ball as thecore component. However, that patent teaches the use of a solid metalball as the core component which provides substantially differentproperties than a polymeric core. Moreover, that patent also teaches theuse of density reducing filler materials incorporated elsewhere in thegolf ball. Although perhaps satisfactory in some respects, in otherrespects, it is undesirable to add density reducing fillers to offsetthe weight of the center core component. Additionally, it would bedesirable to simply avoid the use of density reducing fillers ifpossible as they tend to lower the resilience of the golf ball.

[0024] Moreover, golf balls utilized in tournament or competitive playtoday are regulated for consistency purposes by the United States GolfAssociation (U.S.G.A.). In this regard, there are five (5) U.S.G.A.specifications which golf balls must meet under controlled conditions.These are size, weight, velocity, driver distance and symmetry.

[0025] Under the U.S.G.A. specifications, a golf ball can not weigh morethan 1.62 ounces (with no lower limit) and must measure at least 1.68inches in diameter (with no upper limit). However, as a result of theopenness of the upper or lower parameters in size and weight, a varietyof golf balls can be made. For example, golf balls are manufacturedtoday by the Applicants which are slightly larger (i.e., approximately1.72 inches in diameter) while meeting the weight, velocity, distanceand symmetry specifications set by the U.S.G.A.

[0026] Additionally, according to the U.S.G.A., the initial velocity ofthe ball must not exceed 250 ft/sec. with a 2% maximum tolerance (i.e.,255 ft/sec.) when struck at a set club head speed on a U.S.G.A. machine.Furthermore, the overall distance of the ball must not exceed 280 yardswith a 6% tolerance (296.8 yards) when hit with a U.S.G.A. specifieddriver at 160 ft/sec. (clubhead speed) at a 10 degree launch angle astested by the U.S.G.A. Lastly, the ball must pass the U.S.G.A.administered symmetry test, i.e., fly consistency (in distance,trajectory and time of flight) regardless of how the ball is placed onthe tee.

[0027] While the U.S.G.A. regulates five (5) specifications for thepurposes of maintaining golf ball consistency, alternativecharacteristics (i.e., spin, feel, durability, distance, sound,visibility, etc.) of the ball are constantly being improved upon by golfball manufacturers. This is accomplished by altering the type ofmaterials utilized and/or improving construction of the balls. Forexample, the proper choice of the materials for the cover(s) and core(s)are important in achieving certain distance, durability and playabilityproperties. Other important factors controlling golf ball performanceinclude, but are not limited to, cover thickness and hardness, corestiffness (typically measured as compression), ball size and surfaceconfiguration.

[0028] Accordingly, a wide variety of golf balls have been designed andare available to suit an individual player's game. In essence, differenttypes of balls have been specifically designed or “tailor made” for highhandicap versus low handicap golfers, men versus women, seniors versusjuniors, etc. Moreover, improved golf balls are continually beingproduced by golf ball manufacturers with technological advancements inmaterials and manufacturing processes.

[0029] Two of the principal properties involved in a golf ball'sperformance are resilience and compression. Resilience is generallydefined as the ability of a strained body, by virtue of high yieldstrength and low elastic modulus, to recover its size and form followingdeformation. Simply stated, resilience is a measure of energy retainedto the energy lost when the ball is impacted with the club.

[0030] In the field of golf ball production, resilience is determined bythe coefficient of restitution (C.O.R.), the constant “e” which is theratio of the relative velocity of an elastic sphere after direct impactto that before impact. As a result, the coefficient of restitution (“e”)can vary from 0 to 1, with 1 being equivalent to a perfectly orcompletely elastic collision and 0 being equivalent to a perfectly orcompletely inelastic collision.

[0031] Resilience (C.O.R.), along with additional factors such as clubhead speed, club head mass, angle of trajectory, ball size, density,composition and surface configuration (i.e., dimple pattern and area ofcoverage) as well as environmental conditions (i.e., temperature,moisture, atmospheric pressure, wind, etc.) generally determine thedistance a golf ball will travel when hit. Along this line, the distancea golf ball will travel under controlled environmental conditions is afunction of the speed and mass of the club and the size, density,composition and resilience (C.O.R.) of the ball and other factors. Thevelocity of the club, the mass of the club and the angle of the ball'sdeparture are essentially provided by the golfer upon striking. Sinceclub head, club head mass, the angle of trajectory and environmentalconditions are not determinants controllable by golf ball producers andthe ball size and weight are set by the U.S.G.A., these are not factorsof principal concern among golf ball manufacturers. The factors ordeterminants of interest with respect to improved distance are generallythe coefficient of restitution (C.O.R.), spin and the surfaceconfiguration (dimple pattern, ratio of land area to dimple area, etc.)of the ball.

[0032] The coefficient of restitution (C.O.R.) in solid core balls(i.e., molded cores and covers) is a function of the composition of themolded core and of the cover. The molded core and/or cover may becomprised of one or more layers such as in multi-layered balls.

[0033] In balls containing a wound core (i.e., balls comprising a liquidor solid center, elastic windings, and a cover), the coefficient ofrestitution is a function of not only the composition of the center andcover, but also the composition and tension of the elastomeric windings.As in the solid core balls, center and cover of a wound core ball mayalso consist of one or more layers.

[0034] The coefficient of restitution of a golf ball can be analyzed bydetermining the ratio of the outgoing velocity to the incoming velocity.In the examples of this writing, the coefficient of restitution of agolf ball was measured by propelling a ball horizontally at a speed of125+/−1 feet per second (fps) against a generally vertical, hard, flatsteel plate and measuring the ball's incoming and outgoing velocityelectronically. Speeds were measured with a pair of Oehler Mark 55ballistic screens (available from Oehler Research Austin Tex.), whichprovide a timing pulse when an object passes through them. The screensare separated by 36″ and are located 25.25″ and 61.25″ from the reboundwall. The ball speed was measured by timing the pulses from screen 1 toscreen 2 on the way into the rebound wall (as the average speed of theball over 36″), and then the exit speed was timed from screen 2 toscreen 1 over the same distance. The rebound wall was tilted 2 degreesfrom a vertical plane to allow the ball to rebound slightly downward inorder to miss the edge of the cannon that fired it.

[0035] As indicated above, the incoming speed should be 125+/−1 fps.Furthermore, the correlation between C.O.R. and forward or incomingspeed has been studied and a correction has been made over the +/−fpsrange so that the C.O.R. is reported as if the ball had an incomingspeed of exactly 125.0 fps.

[0036] The coefficient of restitution must be carefully controlled inall commercial golf balls if the ball is to be within the specificationsregulated by the U.S.G.A. As discussed to some degree above, theU.S.G.A. standards indicate that a “regulation” ball cannot have aninitial velocity exceeding 255 feet per second in an atmosphere of 75°F. when tested on a U.S.G.A. machine. Since the coefficient ofrestitution of a ball is related to the ball's initial velocity, it ishighly desirable to produce a ball having sufficiently high coefficientof restitution (C.O.R.) to closely approach the U.S.G.A. limit oninitial velocity, while having an ample amount of softness (i.e.,hardness) to produce the desired degree of playability (i.e., spin,etc.).

[0037] Furthermore, as mentioned above, the maximum distance a golf ballcan travel (carry and roll) when tested on a U.S.G.A. driving machineset at a club head speed of 160 feet/second is 296.8 yards. While golfball manufacturers design golf balls which closely approach this driverdistance specification, there is no upper limit for how far anindividual player can drive a ball. Thus, while golf ball manufacturersproduced balls having certain resilience characteristics in order toapproach the maximum distance parameter set by the U.S.G.A. undercontrolled conditions, the overall distance produced by a ball in actualplay will vary depending on the specific abilities of the individualgolfer.

[0038] The surface configuration of a ball is also an important variablein affecting a ball's travel distance. The size and shape of the ball'sdimples, as well as the overall dimple pattern and ratio of land area todimpled area are important with respect to the ball's overall carryingdistance. In this regard, the dimples provide the lift and decrease thedrag for sustaining the ball's initial velocity in flight as long aspossible. This is done by displacing the air (i.e., displacing the airresistance produced by the ball from the front of the ball to the rear)in a uniform manner. Moreover, the shape, size, depth and pattern of thedimple affect the ability to sustain a ball's initial velocity.

[0039] As indicated above, compression is another property involved inthe overall performance of a golf ball. The compression of a ball willinfluence the sound or “click” produced when the, ball is properly hit.Similarly, compression can affect the “feel” of the ball (i.e., hard orsoft responsive feel), particularly in chipping and putting.

[0040] Moreover, while compression of itself has little bearing on thedistance performance of a ball, compression can affect the playabilityof the ball on striking. The degree of compression of a ball against theclub face and the softness of the cover strongly influences theresultant spin rate. Typically, a softer cover will produce a higherspin rate than a harder cover. Additionally, a harder core will producea higher spin rate than a softer core. This is because at impact a hardcore serves to compress the cover of the ball against the face of theclub to a much greater degree than a soft core thereby resulting in more“grab” of the ball on the clubface and subsequent higher spin rates. Ineffect the cover is squeezed between the relatively incompressible coreand clubhead. When a softer core is used, the cover is under much lesscompressive stress than when a harder core is used and therefore doesnot contact the clubface as intimately. This results in lower spinrates.

[0041] The term “compression” utilized in the golf ball trade generallydefines the overall deflection that a golf ball undergoes when subjectedto a compressive load. For example, PGA compression indicates the amountof change in golf ball's shape upon striking.

[0042] The development of solid core technology in two-piece balls hasallowed for much more precise control of compression in comparison tothread wound three-piece balls. This is because in the manufacture ofsolid core balls, the amount of deflection or deformation is preciselycontrolled by the chemical formula used in making the cores. Thisdiffers from wound three-piece balls wherein compression is controlledin part by the winding process of the elastic thread. Thus, two-pieceand multilayer solid core balls exhibit much more consistent compressionreadings than balls having wound cores such as the thread woundthree-piece balls.

[0043] Additionally, cover hardness and thickness are important inproducing the distance, playability and durability properties of a golfball. As mentioned above, cover hardness directly affects the resilienceand thus distance characteristics of a ball. All things being equal,harder covers produce higher resilience. This is because soft materialsdetract from resilience by absorbing some of the impact energy as thematerial is compressed on striking.

[0044] However, soft covered balls are generally preferred by the moreskilled golfer because he or she can impact high spin rates that givehim or her better control or workability of the ball. Spin rate is animportant golf ball characteristic for both the skilled and unskilledgolfer. As mentioned, high spin rates allow for the more skilled golfer,such as PGA and LPGA professionals and low handicap players, to maximizecontrol of the golf ball. This is particularly beneficial to the moreskilled golfer when hitting an approach shot to a green. The ability tointentionally produce “back spin”, thereby stopping the ball quickly onthe green, and/or “side spin” to draw or fade the ball, substantiallyimproves the golfer's control over the ball. Thus, the more skilledgolfer generally prefers a golf ball exhibiting high spin rateproperties.

[0045] In view in part of the above information, a number of one-piece,two-piece (a solid resilient center or core with a molded cover),three-piece wound (a liquid or solid center, elastomeric winding aboutthe center, and a molded cover), and multi-layer solid or wound golfballs have been produced to address the various needs of golfersexhibiting different skill levels. The different types of materialsutilized to formulate the core(s), cover(s), etc. of these ballsdramatically alter the balls' overall characteristics.

[0046] It would be useful to develop a golf ball exhibiting a high spinrate at low club head speeds when using short, high lofted irons. Such aball would exhibit not only high spin but would also have a combinationof softness and durability which is better than the softness-durabilitycombination of a golf ball cover made from a hard-soft ionomer blend.Furthermore, it would be beneficial to produce a high spin golf ballthat produces enhanced spin characteristics independent of its specificcover composition alone.

[0047] These and other objects and features of the invention will beapparent from the following summary and description of the invention,the drawings and from the claims.

SUMMARY OF THE INVENTION

[0048] Accordingly, it is a feature of the present invention to providea multi-piece, nonwound, solid golf ball. The core is of a multilayerconstruction consisting of two or more polymeric components. Thecharacteristics of the polymeric components of the core are such thatthe moment of inertia may be adjusted to enhance the backspin of theball when using short irons.

[0049] An additional feature of the invention is to provide a ballhaving a multilayer polymeric core enclosed by a multi-layer cover ofvery thin construction. The ball has an appropriate moment of inertiathat will permit extended flight distance of the ball and good roll whenusing a driver, coupled with a cover having sufficient softness thatwill permit deformation of the ball upon impact, thereby increasing thecontact area between the ball and the club face without subjecting thecover to undesirable cutting or abrasion.

[0050] Another feature of the present invention is the provision for agolf ball of the type described that comprises both multilayer cores andcover(s) in such a manner as to incorporate the desirable featuresassociated with various categories of balls traditionally employed.

[0051] A further feature of the present invention is the provision for agolf ball core structure with an inner or center polymeric core and anouter polymeric core layer, with the inner core having a specificgravity that differs from that of the outer core layer by more than 2.0,preferably more than 3.0, and most preferably more than 6.0, therebygiving the golf ball a moment of inertia differing from that of typicalsolid core balls.

[0052] Yet another feature is the provision for a multilayer core thatis combined with a multilayer cover wherein the outer cover layer has alower hardness value than the inner cover layer. Separately, the innerand outer cover layers are very thin (i.e., about 0.055″ or less inthickness) in construction. More preferably, the cover layers are lessthan 0.045 inches in thickness and most preferably about 0.040 inches inthickness.

[0053] A still further feature of the invention is the provision for agolf ball having a soft outer cover layer with good scuff resistance andcut resistance coupled with relatively high spin rates at low club headspeeds.

[0054] The present invention provides in an additional aspect, a solid,nonwound golf ball, and comprising a multi-core assembly that isconcentrically positioned within the center of the golf ball, and amulti-layer cover assembly disposed about the multi-core assembly. Themass and position of both the multi-core assembly and the multi-layercover assembly are such that the moment of inertia of the golf ball isless than 0.45 oz. in², preferably less than 0.44 oz. in², and morepreferably, less than 0.43 oz. in² for a 1.680″ golf ball.

[0055] In yet another aspect, the present invention provides a golf ballcomprising a center core component which is concentrically disposedabout a reference point located at the geometric center of the golfball. The golf ball further comprises an outer core layer whichgenerally surrounds and is disposed about the center core component. Thegolf ball further comprises a first inner cover layer disposed andpositioned around the outer core layer, and a second outermost dimpledcover layer that is disposed about the first inner cover layer.Preferably, an ionomeric material is used in at least one of the coverlayers. The configuration of the golf ball is such that it has a momentof inertia is preferably less than 0.43 oz. in² for a 1.680″ golf ball.

[0056] In yet another aspect, the present invention provides a golf ballcomprising a center polymeric core component having a specific gravityin the range of from about 1.2 to about 20, preferably about 2.0 toabout 18.0, and a diameter in the range from about 5 mm to about 21 mm,preferably less than 10 mm. The golf ball further comprises an outercore polymeric layer disposed about the center core layer component, theouter core layer having a specific gravity in the range from about 0.9to about 1.2, and an outer diameter in the range from about 30 mm toabout 40 mm. The golf ball further includes an inner cover layerdisposed about the core layer, and an outer cover layer disposed aboutthe inner cover layer. The golf ball more preferably exhibits a momentof inertia of less than 0.43 oz. in², and a coefficient of restitutionof at least 0.760, preferably at least 0.780, and most preferably atleast 0.800.

[0057] In a still further aspect, the present invention relates to amultiple core component, non-wound, golf ball having small, highdensity, spherical center which overcomes the above-referenced problemsand others. In this regard, a smaller (i.e., a diameter of from about 5mm to about 21 mm) and heavier spherical center or center core layer isproduced using a blend composed of a first polymer matrix materialcomprising a mix of polybutadiene and polyisoprene rubbers and metalparticles, or other high specific gravity filler materials. The blend ispreferably devoid of any metal carboxylate cross-linking orco-crosslinking agents generally present in solid core golf ballproduction.

[0058] In this respect, the high density center is encapsulated by oneor more outer core layers and a cover assembly comprising one or morelayers. The outer core layer(s) comprise a second polymer matrixmaterial. The size and weight of the outer core layer(s) comprising asecond polymeric matrix material and/or cover layers are adjusted inorder to produce an overall golf ball which meets, or is less than, the1.62 ounce maximum weight limitation specified by the U.S.G.A.

[0059] It has been found that the combination of the present inventionproduces a golf ball with a decreased moment of inertia and/or a lowerradius of gyration. This results in the generation of higher spinwithout substantially affecting the resiliency of the ball.Additionally, the golf ball of the present invention exhibits asubstantially similar or enhanced feel (i.e., softer compression) andoverall durability.

[0060] In an additional aspect, the claimed subject matter of thepresent invention provides a golf ball comprising a dual polymeric coreand a cover. The dual core has an inner, high density, spherical centercore layer and at least one outer core layer. The high density,spherical center comprises a blend of high density powdered metal and/orother heavy weight filler materials and a first polymer matrix materialselected from thermosets, thermoplastics, and combinations thereof.Preferably, the first polymer matrix material comprises a blend of about90 to about 10 weight percent polybutadiene and of about 10 to about 90weight percent polyisoprene. More preferably, the first polymer matrixmaterial comprises of a blend of about 70 to about 30 weight percentpolybutadiene and from about 30 to about 70 weight percent polyisoprene.

[0061] Moreover, in this aspect, the inner, high density, center corelayer is preferably produced without the use of metal carboxyliccrosslinking agents that are generally utilized in solid golf ball coreproduction. These crosslinking agents are the reaction product of anunsaturated carboxylic acid or fatty acids and an oxide or carbonate ofa metal such as zinc. Included are metal salts of unsaturated fattyacids, for example zinc, aluminum, and calcium salts of unsaturatedfatty acids having 3 to 8 carbon atoms, such as acrylic acid andmethacrylic acid.

[0062] The size and weight of the center of this aspect is configured ina manner to produce a low moment of inertia and a reduced rate ofgyration. For example, the inner spherical center core layer has aspecific gravity of greater than 1.2, preferably greater than 4.0, andmost preferably greater than 7.0.

[0063] A lower density outer core layer is disposed about the highdensity spherical center core layer. The outer core layer comprises asecond polymer matrix material selected from thermosets, thermoplastics,and combinations thereof. The second and first polymer matrix materialscan be of the same or different compositions. A cover is then moldedabout the dual core.

[0064] In a still additional aspect, the present invention is directedto an improved dual core golf ball having a relatively small, highdensity spherical center or nucleus containing powdered tungsten (orother high density powdered metals) in a first elastomeric matrix, suchas a blend of polybutadiene and polyisoprene. The powdered metalelastomeric matrix is peroxide, sulfur or radiation crosslinked.Preferably no zinc diacrylate (ZDA), zinc dimethyl acrylate (ZDMA) orother unsaturated carboxylic cross-linking agents are included in theinner spherical center.

[0065] One or more outer core layers are disposed about the high densitycenter, followed by one or more cover layers. The outer core and/orcover layers are made lighter and/or thicker in order to produce anoverall golf ball which conforms with the weight and size requirementsof the U.S.G.A. This combination of weight, and size displacementdecreases the moment of inertia and/or allows the radius of gyration ofthe ball to move closer to the center.

[0066] The solid, non-wound, golf balls of the invention will have amoment of inertia of less than 0.45 oz.in², preferably less than 0.44oz.in² for a standard size golf ball. More preferably the moment ofinertia is less than 0.43 oz.in² for a 1.680″ diameter golf ball. Themoment of inertia for oversized or enlarged golf balls, such as balls1.70-1.72 inches in diameter, is also reduced.

[0067] The moment of inertia (i.e., “MOI”) of a golf ball (also known as“rotational inertia”) is the sum of the products formed by multiplyingthe mass (or sometimes the area) of each element of a figure by thesquare of its distance from a specified line such as the center of agolf ball. This property is directly related to the “radius of gyration”of a golf ball which is the square root of the ratio of the moment ofinertia of a golf ball about a given axis to its mass. It has been foundthat the lower the moment of inertia (or the closer the radius ofgyration is to the center of the ball) the higher the spin rate is ofthe ball with all other properties being held equally.

[0068] In all of the above aspects, the present invention is directed,in part, to decreasing the moment of inertia of a solid, non-wound, golfball by varying the weight arrangement and composition of the core(preferably the inner spherical center core layer and the outer corelayer). By varying the weight, size and density of the components of thegolf ball, the moment of inertia of a golf ball can be decreased.Additionally, different types of matrix materials and/or crosslinkingagents, or lack thereof, can be utilized in the core construction inorder to produce an overall solid, non-wound, golf ball exhibitingenhanced spin and feel while maintaining resiliency and durability.

[0069] In one other further aspect, the claimed subject matter of thepresent application provides a multi-layered covered golf ballcomprising a dual core and a multi-layer cover. Again, the dual corecomprises an inner high density spherical center core layer and at leastone outer core layer. The inner spherical center comprises a blend ofhigh density powdered metal and/or other high density material and afirst matrix material selected from about a fifty percent/fifty percentblend of polybutadiene and polyisoprene. The spherical center has aspecific gravity of greater than 1.2, such as from about 2.0 to about20.0, preferably about 4.0 to 18.0, and most preferably, about 7.6-7.8for a 0.340″-0.344″ (8.6-8.75 mm) center.

[0070] At least one outer core layer of lower density is disposed aboutthe inner spherical center. The outer core layer comprises a secondmatrix material selected from thermosets, thermoplastics, andcombinations thereof.

[0071] The golf ball of this aspect also comprises a multi-layer coverhaving at least an inner cover layer and outer cover layer. The innercover layer is disposed about the outer core layer. The outer coverlayer is disposed about and generally surrounds the inner cover layer.One or more intermediate layers may also be included.

[0072] The golf balls of the present inventions having a high densityelastomeric nucleus, are more durable and softer than solid metalnucleus balls while increasing resiliency. The diameter of the center,or nucleus, is dependant upon the specific gravity of the chosen heavyweight filler and the first matrix material so that the maximum U.S.G.A.golf ball weight is not exceeded. The diameter range of the inner centeror nucleus is from about 0.200″ (about 5 mm) to a maximum of about0.830″ (21 mm), more preferably from about 0.300″ (about 7.6 mm) toabout 0.380″ (about 9.65 mm). The most preferred diameter is {fraction(11/32)}″, or 0.340″ to 0.344″.

[0073] The density of the most preferred 0.340″ to 0.344″ center is lessthan about 20 grams/cc, preferably less than 12 grams/cc and mostpreferably less than 8 grams/cc. The density is set so that it will notexceed the U.S.G.A. golf ball weight requirement. These and otherobjects and features of the invention will be apparent from thefollowing description and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0074] The following is a brief description of the drawings which arepresented for the purposes of illustrating the invention and not for thepurposes of limiting the same.

[0075]FIG. 1 is a cross-sectional view of a golf ball in accordance withthe present invention comprising a dual core component having arelatively small, high density spherical center comprising a powderedmetal or other high density filler material dispersed in a first matrixmaterial comprising polybutadiene and polyisoprene rubbers, a relativelythick outer core layer comprising a second matrix material selected fromthermosets, thermoplastics, or a combination thereof, and asingle-layered cover; and

[0076]FIG. 2 is a cross-sectional view of yet another embodiment golfball in accordance with the present invention comprising a dual corecomponent having a relatively small, high density spherical centercomprising a powdered metal or other high density filler materialdispersed in a first matrix material comprising polybutadiene andpolyisoprene synthetic rubbers, a relatively thick outer core layercomprising a second matrix material selected from thermosets,thermoplastics, or a combination thereof, an inner cover layer and anouter cover layer.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0077] The present invention is directed to improved solid, non-wound,golf balls comprising a polymeric core component with a high densitycenter, or nucleus, and one or more outer core layers and a polymericcover component with either a single or multi-layer cover. The golfballs of the present invention can be of standard or enlarged size. Theballs possess a desired combination of properties, including a highcoefficient of restitution (C.O.R.), a low moment of inertia, good sound(click) and feel, and a high spin rate on short iron shots.

[0078] In this regard, the moment of inertia, sometimes designated “MOI”herein, for the golf balls of the present invention is defined as thesum of the products formed by multiplying the mass of each element bythe square of its distance from a specified line or point. This is alsoknown as rotational inertia. Since the present invention golf ballscomprise a number of components, the MOI of the resulting golf ball isequal to the sum of the moments of inertia of each of its variouscomponents, taken about the same axis or point. All of the moments ofinertia of golf balls referred to herein are with respect to, or aretaken with regard to, the geometric center of the golf ball.

[0079] The term or designation “2×2” or “2×2 construction” as usedherein refers to a golf ball construction utilizing two central corecomponents, e.g. a central core component and a core layer disposedabout the core component, and two cover components, e.g. a first innercover layer and a second outer cover layer. The present inventionhowever is not limited to 2×2 configurations and includes 2×1 (two corecomponents and a single cover component), 3×2 (three core components andtwo cover components), 2×3 configurations (two core components and threecover components), 3×3 configurations (three core components and threecover components), and additional configurations such as 4×2, 4×3, 4×4,2×4, 3×4, etc.

[0080] The term “density reducing filler” as used herein refers tomaterials having relatively low densities, i.e. that are lightweight orhave a specific gravity less than the specific gravity of the basepolybutadiene rubber of 0.91. Examples of these materials includelightweight filler materials typically used to reduce the weight of aproduct in which they are incorporated. Specific examples include, forinstance, foams and other materials having a relatively large voidvolume. Typically, such filler materials have specific gravities lessthan 1.0.

[0081] The golf balls of the present invention utilize a unique dual ormulti-component core configuration. Preferably, the core comprises (i)an interior spherical center component formed from a blend including ahigh density filler material and a first matrix material comprisingpolybutadiene and polyisoprene and (ii) a core layer disposed about thespherical center component, the core layer formed from a second matrixmaterial such as a thermoset material, a thermoplastic material, orcombinations thereof. The cores may further comprise (iii) an optionalouter core layer disposed about the core layer. The outer core layer maybe formed from a third matrix material such as a thermoset material, athermoplastic material, or combinations thereof. The first, second orthird matrix materials can be of the same or different materials.

[0082] The high density center has a specific gravity of greater than1.2 to about 20.0, and preferably about 4.0 to 18.0, most preferably,7.6-7.8 for a 0.340″ to 0.344″ center. The weight of the remainingcomponents are adjusted so that the ball will not exceed the U.S.G.A.golf ball weight requirement.

[0083] In this regard, the present invention is directed to golf ballscomprising a dual core component having a small, high density, sphericalcenter comprising a powdered heavy metal filler or other high densityfiller material. These fillers have a specific gravity of 2.7 or more,preferably 7-8 or more, and most preferably 19.35. The high densityfiller is dispersed in a first matrix material selected from thermosets,thermoplastics, and combinations thereof.

[0084] Preferably, the blend of the high density metal filler materialsand the first matrix material fails to contain any metal carboxylatecross-linking agents (i.e., metal salts of unsaturated fatty acids) suchas zinc diacrylate (ZDA) or zinc dimethyl acrylate (Z DMA).

[0085] A thick outer core layer is then disposed about the sphericalcenter. The outer core layer comprises a second matrix material selectedfrom thermosets, thermoplastics, and combinations thereof. The outerdiameter of the core is from about 1.25″ to 1.60″, and most preferably,1.47″ to 1.56″. A cover comprising one or more layers is subsequentlymolded about the dual core component to form a solid, non-wound golfball.

[0086] In a particularly preferred form of the present invention, thegolf ball comprises a dual core assembly that includes a relativelysmall but heavy spherical center component, a thick but light core layerdisposed about the spherical center component, and a cover assemblydisposed about the dual core assembly. The heavy center of the corecomprises (i) a polymeric material selected from one or more thermosetmaterials, thermoplastic materials or combinations thereof, and (ii) oneor more heavy weight powdered metals having a specific gravity of 2.7 ormore dispersed throughout the polymeric material. Preferably, the heavycenter core is comprised of a blend of polybutadiene and polyisoprene.

[0087] The cover assembly may include a single cover or a multi-layeredcover configuration. Preferably, the novel multi-layer golf ball coversof the present invention include a first or inner layer or ply of a highacid (greater than 16 weight percent acid) ionomer blend or a low acid(16 weight percent acid or less) ionomer blend and second or outer layeror ply comprised of a comparatively softer, low modulus ionomer, ionomerblend or other non-ionomeric thermoplastic or thermosetting elastomersuch as polyurethane or polyester elastomer. Most preferably, the innerlayer or ply includes a blend of low and/or high acid ionomers and has aShore D hardness of 58 or greater and the outer cover layer comprised ofionomer or polyurethane and has a Shore D hardness of at least 1 pointsofter than the inner layer. Separately, the inner and outer coverlayers are very thin (i.e., about 0.050″ or less in thickness) inconstruction. More preferably, the cover layers are less than 0.045inches in thickness and most preferably about 0.040 inches in thickness.

[0088] Although the present invention is primarily directed to solid,non-wound, golf balls comprising a dual core component and a multi-layercover as described herein, the present invention also includes golfballs having a dual core component and conventional covers comprisingionomer, balata, various thermoplastic polyurethanes, castpolyurethanes, or any other cover materials capable of being crosslinkedvia radiation after cover molding.

[0089] Accordingly, the present invention is directed to golf ballshaving a dual-core configuration and a single or multi-layer cover whichproduces, upon molding each layer around a high density inner center, agolf ball exhibiting enhanced spin and feel (i.e., lower compression)without adversely affecting the ball's resiliency (i.e., distance)and/or durability (i.e., cut resistance, scuff resistance, etc.)characteristics.

[0090]FIGS. 1 and 2 illustrate preferred embodiments of the golf ballsin accordance with the present invention. It will be understood that allof the figures referenced herein are schematic in nature and none of thereferenced figures are to scale. And so, the thicknesses and proportionsof the various layers and the diameter of the various core componentsare not necessarily as depicted.

[0091] The golf ball 8 comprises a single layer 11 (FIG. 1) or amulti-layered cover 12 (FIG. 2) disposed about a core 10. The core 10 ofthe golf ball is formed (FIG. 2) of a small, high density spherical orcenter core layer center 20 and a thick, low density outer core layer22. The high density spherical center 20 is designed to produce a lowmoment of inertia. This results, in part, in higher spin.

[0092] The multi-layered cover 12 (FIG. 2) comprises two layers: a firstor inner layer or ply 14 and a second or outer layer or ply 16. Theinner layer 14 can be ionomer, ionomer blends, non-ionomer, non-ionomerblends, or blends of ionomer and non-ionomer. The outer layer 16 issofter than the inner layer and can be ionomer, ionomer blends,non-ionomer, non-ionomer blends or blends of ionomer and non-ionomer.

[0093] In a first multi-layered cover embodiment, the inner layer 14 iscomprised of a high acid (i.e. greater than 16 weight percent acid)ionomer resin or high acid ionomer blend. Preferably, the inner layer iscomprised of a blend of two or more high acid (i.e., at least 16 weightpercent acid) ionomer resins neutralized to various extents by differentmetal cations. The inner cover layer may or may not include a metalstearate (e.g., zinc stearate) or other metal fatty acid salt. Thepurpose of the metal stearate or other metal fatty acid salt is to lowerthe cost of production without affecting the overall performance of thefinished golf ball.

[0094] In a second multi-layered cover embodiment, the inner layer 14 iscomprised of a low acid (i.e., 16 weight percent acid or less) ionomerblend. Preferably, the inner layer is comprised of a blend of two ormore low acid (i.e., 16 weight percent acid or less) ionomer resinsneutralized to various extents by different metal cations. The innercover layer may or may not include a metal stearate (e.g., zincstearate) or other metal fatty acid salt.

[0095] It has been found that a hard inner layer in the multi-coverembodiment provides for a substantial increase in resilience (i.e.,enhanced distance) over known multi-layer covered balls. The softerouter layer along with the particular multi-component core of thepresent invention provides the desirable “feel” and high spin ratecharacteristic while maintaining the golf ball's resiliency. The softouter layer allows the cover to deform more during impact and increasesthe area of contact between the club face and the cover, therebyimparting more spin on the ball. As a result, the soft cover providesthe ball with a balata-like feel and playability characteristics withimproved distance and durability.

[0096] Consequently, the overall combination of the high density innercenter, one or more outer core layers and the inner and outer coverlayers results in a golf ball having enhanced resilience (improvedtravel distance) and durability (i.e., cut resistance, etc.)characteristics while maintaining, and in some instances, improving theplayability properties of the ball.

[0097] The specific components and characteristics of the solid,non-wound golf balls of the present invention are more particularly setforth below.

CORE ASSEMBLY

[0098] As noted, the present invention golf balls utilize a unique dualcore configuration. Preferably, the cores comprise (i) an interior, highdensity, spherical center or center core layer component formed from afirst matrix material comprised of thermoset material, thermoplasticmaterial, or combinations thereof and (ii) an outer core layer disposedabout the spherical center component, the core layer being formed from asecond matrix material comprised of thermoset material, thermoplasticmaterial, or combinations thereof. Preferably the first matrix materialis a blend of polybutadiene and polyisoprene.

[0099] The spherical center component further comprises a blend of oneor more heavy weight metals and/or filler materials preferably inparticulate or powder form, dispersed throughout the thermoset orthermoplastic material. Preferably, the blend is devoid of any metalcarboxylate cross-linking agents.

[0100] The outer core layer is disposed immediately adjacent to, and inintimate contact with the center component. Specifically, one or moreouter core layer(s) is disposed about the center core layer. Mostpreferably, the outer core layer(s) is disposed immediately adjacent to,and in intimate contact with, the inner core layer(s). The matrixmaterial of the spherical center and the core layers may be of similaror different composition.

[0101] The core layers of the golf balls of the present inventiongenerally are more resilient than that of the cover layers, exhibiting aPGA compression of about 85 or less, preferably about 30 to 85, and morepreferably about 40-60.

[0102] The core compositions and resulting molded core layers of thepresent invention are manufactured using relatively conventionaltechniques. In this regard, the core compositions of the inventionpreferably are based on a variety of materials, particularly theconventional rubber based materials such as cis-1,4 polybutadiene andmixtures of polybutadiene with other elastomers blended together withcrosslinking agents, a free radical initiator, specific gravitycontrolling fillers and the like. However, the use of metal carboxylatecrosslinking agents are preferably not included in the center spherecore layer.

[0103] Natural rubber, isoprene rubber, EPR, EPDM, styrene-butadienerubber, or similar thermoset materials may be appropriately incorporatedinto the base rubber composition of the butadiene rubber to form therubber component. It is preferred to use butadiene rubber as a basematerial of the composition for both the central core layer and theouter core layer. Thus, the same rubber composition, including therubber base, free radical initiator, and modifying ingredients, exceptfor the specific gravity controlling filler and crosslinking agent, canbe used in both the central and outer core layers. However, differentcompositions can readily be used in the different layers, includingthermoplastic materials such as a thermoplastic elastomer or athermoplastic rubber, or a thermoset rubber or thermoset elastomermaterial.

[0104] Some examples of materials suitable for use as an outer corelayer include the above materials as well as polyether or polyesterthermoplastic urethanes, thermoset polyurethanes or metallocene polymersor blends thereof. For example, suitable metallocene polymers includefoams of thermoplastic elastomers based on metallocene single sitecatalyst based foams. Such metallocene based foam resins arecommercially available and are readily suitable for forming the outercore layer.

[0105] Examples of a thermoset material include a rubber based, castableurethane or a silicone rubber. The silicone elastomer may be anythermoset or thermoplastic polymer comprising, at least partially, asilicone backbone. Preferably, the polymer is thermoset and is producedby intermolecular condensation of silanols. A typical example is apolydimethylsiloxane crosslinked by free radical initiators, or by thecrosslinking of vinyl or allyl groups attached to the silicone throughreaction with silyihydride groups, or via reactive end groups. Thesilicone may include a reinforcing or non-reinforcing filler.Additionally, the present invention also contemplates the use of apolymeric foam material, such as the metallocene based foamed resin forthe outer core layers.

[0106] More particularly, a wide array of thermoset materials can beutilized in the core components of the present invention. Examples ofsuitable thermoset materials include polybutadiene, polyisoprene,styrene/butadiene, ethylene propylene diene terpolymers, natural rubberpolyolefins, polyurethanes, silicones, polyureas, or virtually anyirreversibly cross-linkable resin system. It is also contemplated thatepoxy, phenolic, and an array of unsaturated polyester resins could beutilized.

[0107] The thermoplastic material utilized in the present invention golfballs and, particularly their dual cores, may be nearly anythermoplastic material. Examples of typical thermoplastic materials forincorporation in the golf balls of the present invention include, butare not limited to, ionomers, polyurethane thermoplastic elastomers, andcombinations thereof. It is also contemplated that a wide array of otherthermoplastic materials could be utilized, such as polysulfones,polyamide-imides, polyarylates, polyaryletherketones, polyarylsulfones/polyether sulfones, polyether-imides, polyimides, liquidcrystal polymers, polyphenylene sulfides; and specialty high-performanceresins, which would include fluoropolymers, polybenzimidazole, andultrahigh molecular weight polyethylenes.

[0108] Additional examples of suitable thermoplastics includemetallocenes, polyvinyl chlorides, polyvinyl acetates,acrylonitrile-butadiene-styrenes, acrylics, styrene-acrylonitriles,styrene-maleic anhydrides, polyamides (nylons), polycarbonates,polybutylene terephthalates, polyethylene terephthalates, polyphenyleneethers/polyphenylene oxides, reinforced polypropylenes, and high-impactpolystyrenes.

[0109] Preferably, the thermoplastic materials have relatively highmelting points, such as a melting point of at least about 300° F.Several examples of these preferred thermoplastic materials and whichare commercially available include, but are not limited to, Capron™ (ablend of nylon and ionomer), Lexan™ polycarbonate, Pebax™, and Hytrel™.The polymers or resin system may be cross-linked by a variety of meanssuch as by peroxide agents, sulphur agents, radiation or othercross-linking techniques, if applicable. However, the use of peroxidecrosslinking agents is generally preferred in the present invention.

[0110] Any or all of the previously described components in the cores ofthe golf ball of the present invention may be formed in such a manner,or have suitable fillers added, so that their resulting density isdecreased or increased. For example, heavy weight metals and/or fillermaterials are incorporated into the inner spherical center. This isdiscussed in more detail below.

[0111] Additionally, the outer core layers are formed or otherwiseproduced to be light in weight. For instance, the components could befoamed, either separately or in-situ. Related to this, a foamed lightweight filler agent or density reducing filler may also be added to theouter core layers.

[0112] The specially produced core components of the present inventionare manufactured using relatively conventional techniques. In thisregard, the preferred core compositions (i.e., center, core layer, outercore layer, etc.) of the invention may be based on polybutadiene, andmixtures of polybutadiene with other elastomers. It is preferred thatthe base elastomer have a relatively high molecular weight. The broadrange for the molecular weight of suitable base elastomers is from about50,000 to about 500,000. A more preferred range for the molecular weightof the base elastomer is from about 100,000 to about 500,000. As a baseelastomer for the core composition, cis-polybutadiene is preferablyemployed, or a blend of cis-polybutadiene with other elastomers such aspolyisoprene may also be utilized. Most preferably, cis-polybutadienehaving a weight-average molecular weight of from about 100,000 to about500,000 is employed. Along this line, it has been found that thecombination of a high cis-polybutadiene manufactured and sold by DowFrance 13131 Berre l'Etang Cedex, France, tradename Cariflex BR-1220,and a polyisoprene available from The Goodyear Tire & Rubber Co., Akron,Ohio, under the designation “Natsyn™ 2200” is particularly well suited.

[0113] Although the use of metal carboxylate crosslinking agents is notpreferred for the center core layer, these crosslinkers are included inthe additional outer core layers. The unsaturated carboxylic acidcomponent of the core composition (a co-crosslinking agent) is thereaction product of the selected carboxylic acid or acids and an oxideor carbonate of a metal such as zinc, magnesium, barium, calcium,lithium, sodium, potassium, cadmium, lead, tin, and the like.Preferably, the oxides of polyvalent metals such as zinc, magnesium andcadmium are used, and most preferably, the oxide is zinc oxide.

[0114] Exemplary of the unsaturated carboxylic acids which find utilityin the present core compositions are acrylic acid, methacrylic acid,itaconic acid, crotonic acid, sorbic acid, and the like, and mixturesthereof. Preferably, the acid component is either acrylic or methacrylicacid. Usually, from about 12 to about 40, and preferably from about 15to about 35 parts by weight of the carboxylic acid salt, such as zincdiacrylate, is included in the outer core layers. The unsaturatedcarboxylic acids and metal salts thereof are generally soluble in theelastomeric base, or are readily dispersed.

[0115] The free radical initiator included in the core compositions isany known polymerization initiator (a co-crosslinking agent) whichdecomposes during the cure cycle. The term “free radical initiator” asused herein refers to a chemical which, when added to a mixture of theelastomeric blend and a metal salt of an unsaturated, carboxylic acid,promotes crosslinking of the elastomers by the metal salt of theunsaturated carboxylic acid. The amount of the selected initiatorpresent is dictated only by the requirements of catalytic activity as apolymerization initiator. Suitable initiators include peroxides,persulfates, azo compounds and hydrazides. Peroxides which are readilycommercially available are conveniently used in the present invention,generally in amounts of from about 0.5 to about 4.0 and preferably inamounts of from about 1.0 to about 3.0 parts by weight per each 100parts of elastomer and based on 40% active peroxide with 60% inertfiller.

[0116] Exemplary of suitable peroxides for the purposes of the presentinvention are dicumyl peroxide, n-butyl 4,4′-bis (butylperoxy) valerate,1,1-bis(tbutylperoxy)-3,3,5-trimethyl cyclohexane, di-t-butyl peroxideand 2,5-di-(tbutylperoxy)-2,5 dimethyl hexane and the like, as well asmixtures thereof. It will be understood that the total amount ofinitiators used will vary depending on the specific end product desiredand the particular initiators employed.

[0117] Examples of such commercially available peroxides are Luperco™230 or 231 XL sold by Atochem, Lucidol Division, Buffalo, N.Y., andTrigonox™ 17/40 or 29/40 sold by Akzo Chemie America, Chicago, Ill. Inthis regard Luperco™ 230 XL and Trigonox™ 17/40 are comprised of n-butyl4,4-bis (butylperoxy) valerate; and, Luperco™ 231 XL and Trigonox™ 14/40are comprised of 1,1-bis(tbutylperoxy)-3,3,5-trimethyl cyclohexane. Theone hour half life of Luperco™ 231 XL is about 112° C., and the one hourhalf life of Trigonox™ 17/40 is about 129° C. Trigonox™ 42-40 B ispreferred and is chemically tert-Butyl peroxy-3,5,5, trimethylhexanoate.

[0118] The core compositions of the present invention may additionallycontain any other suitable and compatible modifying ingredientsincluding, but not limited to, metal oxides, fatty acids, anddiisocyanates and polypropylene powder resin. For example, Papi™ 94, apolymeric diisocyanate, commonly available from Dow Chemical Co.,Midland, Mich., is an optional component in the rubber compositions. Itcan range from about 0 to 5 parts by weight per 100 parts by weightrubber (phr) component, and acts as a moisture scavenger. In addition,it has been found that the addition of a polypropylene powder resinresults in a core which is too hard (i.e. exhibits low compression) andthus allows for a reduction in the amount of crosslinking agent utilizedto soften the core to a normal or below normal compression.

[0119] Furthermore, because polypropylene powder resin can be added tothe core composition without an increase in weight of the molded coreupon curing, the addition of the polypropylene powder allows for theaddition of higher specific gravity fillers, such as mineral fillers.Since the crosslinking agents utilized in the polybutadiene corecompositions are expensive and/or the higher specific gravity fillersare relatively inexpensive, the addition of the polypropylene powderresin substantially lowers the cost of the golf ball cores whilemaintaining, or lowering, weight and compression.

[0120] The polypropylene (C₃H₅) powder suitable for use in the presentinvention has a specific gravity of about 0.90 g/cm³, a melt flow rateof about 4 to about 12 and a particle size distribution of greater than99% through a 20 mesh screen. Examples of such polypropylene powderresins include those sold by the Amoco Chemical Co., Chicago, Ill.,under the designations “6400 P”, “7000 P” and “7200 P”. Generally, from0 to about 25 parts by weight polypropylene powder per each 100 parts ofelastomer are included in the present invention.

[0121] Various activators may also be included in the compositions ofthe present invention. For example, zinc oxide, calcium oxide and/ormagnesium oxide are activators for the polybutadiene. The activator canrange from about 2 to about 30 parts by weight per 100 parts by weightof the rubbers (phr) component.

[0122] Fatty acids or metallic salts of fatty acids may also be includedin the compositions, functioning to improve moldability and processing.Generally, free fatty acids having from about 10 to about 40 carbonatoms, and preferably having from about 15 to about 20 carbon atoms, areused. Exemplary of suitable fatty acids are stearic acid and linoleicacids, as well as mixtures thereof. Exemplary of suitable metallic saltsof fatty acids include zinc stearate. When included in the corecompositions, the fatty acid component is present in amounts of fromabout 1 to about 25, preferably in amounts from about 2 to about 15parts by weight based on 100 parts rubber (elastomer).

[0123] It is preferred that the core compositions include zinc stearateas the metallic salt of a fatty acid in an amount of from about 2 toabout 20 parts by weight per 100 parts of rubber.

[0124] Diisocyanates may also be optionally included in the corecompositions. The diisocyanates act here as moisture scavengers. Whenutilized, the diioscyanates are included in amounts of from about 0.2 toabout 5.0 parts by weight based on 100 parts rubber. Exemplary ofsuitable diisocyanates is 4,4′-diphenylmethane diisocyanate and otherpolyfunctional isocyanates know to the art.

[0125] Furthermore, the dialkyl tin difatty acids set forth in U.S. Pat.No. 4,844,471, the dispersing agents disclosed in U.S. Pat. No.4,838,556, and the dithiocarbamates set forth in U.S. Pat. No. 4,852,884may also be incorporated into the polybutadiene compositions of thepresent invention. The specific types and amounts of such additives areset forth in the above identified patents, which are incorporated hereinby reference.

[0126] The preferred core components of the invention are generallycomprised of 100 parts by weight of a base elastomer (or rubber)selected from polybutadiene and mixtures of polybutadiene with otherelastomers, such as polyisoprene, 12 to 40 parts by weight of at leastone metallic salt of an unsaturated carboxylic acid, and 0.5 to 4.0parts by weight of a free radical initiator (40% active peroxide).However, as mentioned above, the use of at least one metallic salt of anunsaturated carboxylic acid is preferably not included in theformulation of the high density center core layer.

[0127] In addition to polybutadiene; the following commerciallyavailable thermoplastic resins are also particularly suitable for use inthe noted dual cores employed in the golf balls of the presentinvention: Capron™ 8351 (available from Allied Signal Plastics), Lexan™ML5776 (from General Electric), Pebax™ 3533 (a polyether block amidefrom Elf Atochem), and Hytrel™ G4074 (a polyether ester from DuPont).Properties of these four thermoplastics are set forth below in Table 1.TABLE 1 CAPRON ™ 8351 DAM 50% RH ASTM Test MECHANICAL Tensile Strength,Yield, psi (MPa) 7,800 (54) — D-638 Flexural Strength, psi (MPa) 9,500(65) — D-790 Flexural Modulus, psi (MPa) 230,000 (1,585) — D-790Ultimate Elongation, % 200 — D-638 Notched Izod Impact, ft-lbs/in (J/M)No Break — D-256 Drop Weight Impact, ft-lbs (J) 150 (200) — D-3029 DropWeight Impact, @ −40° F., ft-lbs (J) 150 (200) — D-3029 PHYSICALSpecific Gravity 1.07 — D-792 THERMAL Melting Point, ° F. (° C.) 420(215) — D-789 Heat Deflection @ 264 psi ° F. (° C.) 140 (60) — D-648Lexan ™ ML5776 PROPERTY TYPICAL DATA UNIT METHOD MECHANICAL TensileStrength, yield, Type I, 0.125″ 8500 psi ASTM D 638 Tensile Strength,break, Type I, 0.125″ 9500 psi ASTM D 638 Tensile Elongation, yield,Type I, 0.125″ 110.0 % ASTM D 638 Flexural Strength, yield, 0.125″ 12000psi ASTM D 790 Flexural Modulus, 0.125″ 310000 psi ASTM D 790 IMPACTIzod Impact, unnotched, 73F 60.0 ft-lb/in ASTM D 4812 Izod Impact,notched, 73F 15.5 ft-lb/in ASTM D 256 Izod Impact, notches 73F, 0.250″12.0 ft-lb/in ASTM D 256 Instrumented Impact Energy @ Peak, 73F 48.0ft-lbs ASTM D 3763 THERMAL HDT, 264 psi, 0.250″, unannealed 257 deg F.ASTM D 648 Thermal Index, Elec Prop 80 deg C. UL 7468 Thermal Index,Mech Prop with Impact 80 deg C. UL 7468 Thermal Index, Mech Prop withoutImpact 80 deg C. UL 7468 PHYSICAL Specific Gravity, solid 1.19 — ASTM D792 Water Absorption, 24 hours @ 73F 0.150 % ASTM D 570 Mold Shrinkage,flow, 0.125″ 5.7 in/in E-3 ASTM D 955 Melt Flow Rate, nom = I, 300 C/1.2kgf(0) 7.5 g/10 min ASTM D 1238 FLAME CHARACTERISTICS UL File Number,USA E121562 — — 94HB Rated (tested thickness) 0.060 inch UL94 PEBAX ™RESINS ASTM TEST PROPERTY METHOD UNITS 3533 Specific Gravity D792 WaterAbsorption Equilibrium 0.5 (20° C., 50% R.H.>) 24 Hr. Immersion D570 1.2Hardness D2240 35D Tensile Strength, Ultimate D638 psi 5600 Elongation,Ultimate D638 % 580 Flexural Modulus D790 psi 2800 Izod Impact, NotchedD256 ft-   20° C. lb./in. NB −40° C. NB Abrasion Resistance D1044Mg/1000 104 H18/1000 g Cycles Tear Resistance Notched D624C lb./in. 260Melting Point D3418 ° F. 306 Vicat Softening Point D1525 ° F. 165 HDT 66psi D648 ° F. 115 Compression Set D395A % 54 (24 hr., 160° F.) HYTREL ™G4074 Thermoplastic Elastomer ASTM TEST PROPERTY METHOD UNITS 3533PHYSICAL Dens/Sp Gr ASTM D792 1.1800 sp gr 23/23 C Melt Flow ASTM D12385.20 @° - 190 C/2.16 kg g/10/min Wat Abs ASTM D570 2.100% MECHANICALElong@Brk ASTM D638 230.0% Flex Mod ASTM D790 9500 psi TnStr@Brk ASTMD638 2000 psi IMPACT Notch Izod ASTM D256 No Break @ 73.0 F @0.2500inft-lb/in 0.50 @ −40.0 F @0.2500 inft-lb/in HARDNESS Shore ASTM D224040 Shore D THERMAL DTUL@66 ASTM D648 122 F. Melt Point 338.0 F. VicatSoft ASTM D1525 248 F. Melt Point

[0128] In addition, various polyisoprenes may also be included in thecore components of the present invention. Examples of such polyisoprenesare as follows: TRADENAME Composition ELASTOMER PROPERTIES SupplierCompounding & Processing Isolene Sp. gr. 0.92. Ash, 0.5-1.2%. Volatilematter, Depolymerized 0.1% (24 hour at 300° F.), 100% rubber synthetic(flowable form). Grades: Isolene-40 (40,00 cps polyisoprene @ 100° F.;Mol wt. mw 40,000); Isolene- Hardman 75 viscosity (75,000 cps @ 100°F.); DPR- 400 viscosity (400,000 @ 100° F., mol wt. mw 40,000). Gardnercolor (60-8) Natsyn 2200 Sp. gr. 0.91. White, non-staining, solutionGoodyear polymerized, IR with excellent uniformity and R. T. Vanderbiltpurity. Vulcanized with conventional cure systems, Mooney visc (ml-4 @212° F.). 70-90, needs little or no breakdown. Tg. 98° F. Natsyn 2205Sp. gr. 0.91. White, non-staining, virtually DuPont gel free solutionpolymerized IR. Mooney R. T. Vanderbilt viscosity (ml-4 @ 212° F.).70-90, needs little or no breakdown. Tg. 98° F. Natsyn 2210 Sp. gr.0.91. White, non-staining, low DuPont Mooney, solution polymerized, IRwith R. T. Vanderbilt excellent uniformity and purity. Vulcanized withconventional cure systems, Mooney visc (ml-4 @ 212° F.) 50-65, thereforeno breakdown is required. Tg-98E. Nipol IR 2200L Sp. gr. 0.92, Mooneyvisc. ml-4 at 100° C. 70, Goldsmith & Eggleton Cis 1,498%. non-staining.SKI-3 Staining IR: 97.5 cis 1,4; Mooney viscosity, Polyisoprene density915″5. H. A. Astlett SKI-3 Mooney visc. MB 1′4 (100° C.) 65-85; IsopreneRubber Plasticity 0.30-0.41; ultimate elongation, % Nizh USA min. 800;Ultimate tensile strength MPa (kgF/sq.cm.) min at 23° C. 30.4 at 100° C.21.6. SKI-3 (Russian IR) Staining IR, 97.5 cis 1,4. 60 MooneyPolyisoprene viscosity, density 915″5. Alcan SKI-3-S Non-staining 97.5cis 1,4 73 ″ 7 Mooney Polyisoprene viscosity, density 915″5. H. A.Astlett SKI-3-S (Russian IR) Non-staining 97.5 cis 1,4 73 ″ 7 MooneyPolyisoprene viscosity, density 915″5. Alcan

[0129] The inner spherical center preferably can be compression ortransfer molded from an uncured or lightly cured elastomer composition.To achieve higher coefficients of restitution and/or to increasehardness in the core, the manufacturer may include a small amount of ametal oxide such as zinc oxide. Non-limiting examples of other materialswhich may be used in the core composition including compatible rubbersor ionomers, and low molecular weight fatty acids such as stearic acid.Free radical initiator catalysts such as peroxides are admixed with thecore composition so that on the application of heat and pressure, acuring or cross-linking reaction takes place.

[0130] Also included in the matrix materials of the inner sphericalcenters, are one or more heavy weight fillers or powder materials. Suchan inner spherical center exhibits a lower moment of inertia thanconventional two-piece golf balls. The moment of inertia for the presentgolf ball is less than 0.45 oz.in² and more preferably less than 0.44oz.in². Most preferably, the moment of inertia for the golf ball of thepresent invention is less than 0.43 oz.in².

[0131] The powdered metal in the spherical center may be in a wide arrayof types, geometries, forms, and sizes. The powdered metal may be of anyshape so long as the metal may be blended with the other componentswhich form the spherical center.

[0132] Particularly, the metal may be in the form of metal particles,metal flakes, and mixtures thereof. However, again, the forms ofpowdered metal are not limited to such forms. The metal may be in a formhaving a variety of sizes so long as the objectives of the presentinvention are maintained. Preferably, the powdered metal is incorporatedinto the matrix material of the spherical center in finely defined form,as for example, in a size generally less than about 20 mesh, preferablyless than about 200 mesh and most preferably less than about 325 mesh,U.S. standard size. The amount of powdered metal included in thespherical center is dictated by weight restrictions, the type ofpowdered metal, and the overall characteristics of the finished ball.However, the amount of powdered metal is generally from about 100 toabout 3200 parts by weight matrix material, more preferably, from about500 to about 1500 matrix material and most preferably from about 1200 to1400 matrix material for a 0.340″ diameter polybutadiene center.

[0133] The spherical center may include more than one type of powderedmetal. Particularly, the spherical center may include blends of thepowdered metals disclosed in Table 2 below. The blends of powderedmetals may be in any proportion with respect to each other in order forthe spherical center and golf ball to exhibit the characteristics notedherein.

[0134] In this regard, the weight of the inner spherical core componentis increased in the present invention through the inclusion of 100-3200parts per hundred parts matrix material of metal particles and otherheavy weight filler materials. As used herein, the term “heavy weightfiller materials” is defined as any material having a specific gravitygreater than 2.7. Preferably, the particles (or flakes, fragments,fibers, etc.) of powdered metal are added to the inner spherical core inorder to decrease the moment of inertia of the ball without affectingthe ball's feel and durability characteristics.

[0135] The inner spherical core is filled with one or more reinforcingor non-reinforcing heavy weight fillers such as metal (or metal alloy)powders. Representatives of such metal (or metal alloy) powders includebut are not limited to, tungsten powder, bismuth powder, boron powder,brass powder, bronze powder, cobalt powder, copper powder, inconnelmetal powder, iron metal powder, molybdenium powder, nickel powder,stainless steel powder, titanium metal powder, zirconium oxide powder,aluminum flakes, and aluminum tadpoles.

[0136] Examples of several suitable powdered metals which can beincluded in the present invention are as follows: TABLE 2 Metals andAlloys (Powders) Specific Gravity titanium 4.51 tungsten 19.35 bismuth9.78 nickel 8.90 molybdenum 10.2 iron 7.86 copper 8.94 brass 8.2-8.4bronze 8.70-8.74 cobalt 8.92 zinc 7.14 tin 7.31 aluminum 2.70

[0137] The amount and type of powdered metal utilized is dependent uponthe overall characteristics of the high spinning, soft feeling, golfball desired. Generally, lesser amounts of high specific gravitypowdered metals are necessary to produce a decrease in the moment ofinertia in comparison to low specific gravity materials. Furthermore,handling and processing conditions can also effect the type of heavyweight powdered metals incorporated into the spherical center. In thisregard, Applicants have found that the inclusion of approximately1200-1400 phr tungsten powder into the inner spherical center producesthe desired increase in the moment of inertia without involvingsubstantial processing changes. Thus, 1200-1400 phr tungsten powder isthe most preferred heavy filler material at the time of this writing fora 0.340″ diameter polybutadiene center or nucleus.

[0138] Furthermore, powdered iron can also be preferably blended withpowdered tungsten or other powdered materials in the spherical center sothat the spherical center can be attracted to a magnet. The magneticattraction allows for automated assembly of the spherical center to theremaining layers in forming the golf ball. Preferably, the powdered ironis about 4-10% by weight of the spherical center composition when usedas an attraction agent for a magnet.

[0139] The powdered metal constitutes at least 50% by weight of thetotal spherical center composition. Preferably, the powdered metalconstitutes at least 60% of the spherical center composition. Mostpreferably, the powdered metal constitutes at least 70% of the sphericalcenter composition.

[0140] When the preferred high density powdered metal comprises thespherical center, the diameter of the spherical center can varyconsiderably so long as the maximum U.S.G.A. golf ball weight is notexceeded. Preferably, the spherical center has a diameter in the rangeof about 0.200 inches to about 0.830 inches. More preferably, thediameter of the spherical center is from about 0.200 inches to about0.400 inches, most preferably from about 0.300 inches to about 0.380inches, with 0.340-0.344 inches being optimal.

[0141] The spherical center comprising a high density powdered metal hasa density that will not exceed the U.S.G.A. golf ball weightrequirement. Preferably, the density is no more than about 12-20,preferably less than 9 grams/cm³ for a 0.340″-0.344″ diameter nucleus.

[0142] The outer diameter of the center core and the outer diameter ofthe outer core (core diameter) may vary. However, the center core has adiameter of about 5 to 21 mm and preferably about 5 to 15 mm while theouter core has a diameter of about 30 to 40 mm and preferably 35 to 38mm, depending on the size of the center core and the finished size ofthe ball. Typically the center core diameter is about 5 to 12 mm.

[0143] The core having a two-layer structure composed of the inner coreand the outer core is referred to as the solid core in the presentinvention. The above expression is in contrast to a thread-wound core(core formed by winding a rubber thread around the center portion whichis solid or filled with a liquid material).

[0144] The double cores of the inventive golf balls typically have acoefficient of restitution of about 0.730 or more, more preferably 0.770or more and a PGA compression of about 95 or less, and more preferably70 or less. The double cores have a weight of 25 to 40 grams andpreferably 30 to 40 grams and a Shore C hardness of less than 80, withthe preferred Shore C hardness being about 50 to 75.

[0145] As mentioned above, the present invention includes golf ballembodiments that utilize two or more core components. For example, inaccordance with the present invention, a core assembly is provided thatcomprises a central core component and one or more core layers disposedabout the central core component. Details for the second and third ormore core layers are also included herein in the description of the corelayer utilized in a dual core configuration.

[0146] In producing golf ball centers utilizing the presentcompositions, the ingredients may be intimately mixed using, forinstance, two roll mills or a Banbury™ mixer until the composition isuniform, usually over a period of from about 5 to about 20 minutes. Thesequence of addition of components is not critical. A preferred blendingsequence is described below.

[0147] The matrix material or elastomer, powdered metal zinc salt (ifdesired), the high specific gravity additive such as powdered metal,metal oxide, fatty acid, and the metallic dithiocarbamate (if desired),surfactant (if desired), and tin difatty acid (if desired), are blendedfor about 7 minutes in an internal mixer such as a Banbury™ mixer. As aresult of shear during mixing, the temperature rises to about 200° F.The mixing is desirably conducted in such a manner that the compositiondoes not reach incipient polymerization temperatures during the blendingof the various components. The initiator and diisocyanate are then addedand the mixing continued until the temperature reaches about 220° F.whereupon the batch is discharged onto a two roll mill, mixed for aboutone minute and sheeted out.

[0148] The sheet is rolled into a “pig” and then placed in a Barwell™preformer and slugs of the desired weight are produced. The slugs to beused for the center core layer are then subjected to compression moldingat about 140° C. to about 170° C. for about 10 to 50 minutes. Note thatthe temperature in the molding process is not always required to beconstant, and may be changed in two or more steps. In fact, the slugsfor the outer core layer are frequently preheated for about one halfhour at about 75° C. prior to molding. After molding, the molded centersare cooled, the cooling effected at room temperature for about 4 hoursor in cold water for about one hour. The molded centers are subjected toa centerless grinding operation whereby a thin layer of the molded coreis removed to produce a round center. Alternatively, the centers areused in the as-molded state with no grinding needed to achieveroundness.

[0149] The solid inner centers are generally from 0.200 to 0.830 inchesin diameter, preferably 0.300 to 0.380 inches, and most preferably 0.320to 0.360 inches, with a weight of 1.2 grams to 5.9 grams, preferably 1.8to 3.6 grams, and most preferably 2.6 to 3.0 grams for a 0.340″-0.344″diameter nucleus. The specific gravity of the inner spherical center isfrom 1.2 to 20.0, preferably 5 to 12, and most preferably 7.6 to 7.9 fora 0.340″-0.344″ diameter nucleus.

[0150] The center is converted into a dual core by providing at leastone layer of core material thereon, ranging in thickness from about 0.69to about 0.38 inches and preferably from about 0.65 to about 0.60inches. The outer core layers may be of similar or different matrixmaterial as the spherical center. Preferably the outer core layercomprises polybutadiene which has been weight adjusted to compensate forthe heavy weight spherical center.

[0151] The outer core layer can be applied around the spherical centerby several different types of molding processes. For example, thecompression molding process for forming the cover layer(s) of a golfball that is set forth in U.S. Pat. No. 3,819,795 can be adapted for usein producing the core layer(s) of the present invention.

[0152] In such a modified process, preforms or slugs of the outer corematerial, i.e., the thermoset material utilized to form the outer corelayer, are placed in the upwardly open, bottom cavities of a lower moldmember of a compression molding assembly, such as a conventional golfball or core platen press. The upwardly facing hemispherical cavitieshave inside diameters substantially equal to the finished core to beformed. In this regard, the inside diameters of the cavities areslightly larger (i.e., approximately 0.010″ diameter) than the desiredfinished core size in order to account for material shrinkage.

[0153] An intermediate mold member comprising a center Teflon™-coatedplate having oppositely-affixed hemispherical protrusions extendingupwardly on the upper surface and extending downwardly on the lowersurface, each hemispherical protrusion about 0.340 inches in diameter,is placed over the lower mold member and on top of the preforms locatedin the bottom molding cavities. The size and outside diameters of thehemispherical protrusions are substantially equal to the centers to beutilized and thus can vary with the various sizes of the centers to beused.

[0154] Additional preforms of the same outer core material aresubsequently placed on top of the upperly-projecting 0.340″hemispherical protrusions affixed to the upper surfaces of theTeflon™-coated plate of the intermediate mold member. The additionalpreforms are then covered by the downwardly open cavities of the topmold member. Again the downward facing cavities of the top mold memberhave inside diameters substantially equal to the core to be formed.

[0155] Specifically, the bottom mold member is engaged with the top moldmember with the intermediate mold member having the oppositelyprotruding hemispheres being present in the middle of the assembly. Themold members are then compressed together to form hemispherical corehalves.

[0156] In this regard, the mold assembly is placed in a; press and coldformed at room temperature using approximately 10 tons of pressure in asteam press. The molding assembly is closed and heated below the cureactivation temperature of about 150° F. for approximately four minutesto soften and mold the outer core layer materials. While still undercompression, but at the end of the compression cycle, the mold membersare water cooled to a temperature to less than 100° F. in order tomaintain material integrity for the final molding step. This coolingstep is beneficial since cross linking has not yet proceeded to provideinternal chemical bonds to provide full material integrity. Aftercooling, the pressure is released.

[0157] The molding assembly is then opened, the upper and lower moldmembers are separated, and the intermediate mold member is removed whilemaintaining the formed outer core layer halves in their respectivecavities. Each of the halves has an essentially perfectly formedone-half shell cavity or depression in its uncured thermoset material.These one-half shell cavities or depressions were produced by thehemispherical protrusions of the intermediate mold member.

[0158] Previously molded centers of about 0.340″ in diameter, are thenplaced into the bottom cavities or depressions of the uncured thermosetmaterial. The top portion of the molding assembly is subsequentlyengaged with the bottom portion and the material that is disposedtherebetween is cured for about 12 minutes at about 320° F. Those ofordinary skill in the art relating to free radical curing agents forpolymers are conversant with adjustments of cure times and temperaturesrequired to effect optimum results with any specific free radical agent.The combination of the high temperature and the compression force joinsthe core halves, and bonds the cores to the center. This process resultsin a substantially continuously outer core layer being formed around thecenter component.

[0159] In an alternative, and in some instances, more preferablecompression molding process, the Teflon™-coated plate of theintermediate mold member has only a set of downwardly projectinghemispherical protrusions and no oppositely affixed upwardly-projectinghemispherical protrusions. Substituted for the upwardly-projectingprotrusions are a plurality of hemispherical recesses in the uppersurface of the plate. Each recess is located in the upper surface of theplate opposite a protrusion extending downwardly from the lower surface.The recess has an inside diameter substantially equal to the center tobe utilized and is configured to receive the bottom half of the center.

[0160] The previously molded centers of about 0.340″ in diameter arethen placed in the cavities located on the upper surface of the plate ofthe intermediate mold member. Each of the centers extends above theupper surface of the plate of the intermediate mold member and ispressed into the lower surface of the upper preform when the molds areinitially brought together during initial compression.

[0161] The molds are then separated and the plate removed, with thecenters being retained (pressed into) the half shells of the upperpreforms. Mating cavities or depressions are also formed in the halfshells of the lower preforms by the downwardly projecting protrusions ofthe intermediate mold member. With the plate now removed, the topportion of the molding assembly is then joined with the bottom portion.In so doing, the centers projecting from the half shells of the upperperforms enter into the cavities or depressions formed in the halfshells of the lower preforms. The material included in the molds issubsequently compressed, treated and cured as stated above to form agolf ball core having a centrally located center and an outer corelayer. This process can continue for additional added core layers.

[0162] After molding, the core comprising a centrally located centersurrounded by at least one outer core layer is removed from the mold andthe surface thereof preferably is treated to facilitate adhesion thereofto the covering materials. Surface treatment can be effected by any ofthe several techniques known in the art, such as corona discharge, ozonetreatment, sand blasting, brush tumbling, and the like. Preferably,surface treatment is effected by grinding with an abrasive wheel.

Cover Assembly

[0163] A. Multi-Covers

[0164] i. Inner Cover Layer

[0165] The inner cover layer is harder than the outer cover layer andgenerally has a thickness in the range of 0.01 to 0.10 inches,preferably 0.03 to 0.07 inches for a 1.68 inch ball and 0.05 to 0.10inches for a 1.72 inch (or more) ball. The core and inner cover layertogether form an inner ball having a coefficient of restitution of 0.780or more and more preferably 0.790 or more, and a diameter in the rangeof 1.48-1.64 inches for a 1.68 inch ball and 1.50-1.70 inches for a 1.72inch (or more) ball. The inner cover layer has a Shore D hardness of 60or more. It is particularly advantageous if the golf balls of theinvention have an inner layer with a Shore D hardness of 65 or more. Theabove-described characteristics of the inner cover layer provide aninner ball having a PGA compression of 100 or less. It is found thatwhen the inner ball has a PGA compression of 90 or less, excellentplayability results.

[0166] The inner layer compositions include the high acid ionomers suchas those developed by E. I. DuPont de Nemours & Company under thetrademark “Surlyn™ ” and by Exxon Corporation under the trademark“Escor™” or trade name “lotek”, or blends thereof. Examples ofcompositions which may be used as the inner layer herein are set forthin detail in a continuation of U.S. application Ser. No. 08/174,765,which is a continuation of U.S. application Ser. No. 07/776,803 filedOct. 15, 1991, and Ser. No. 08/493,089, which is a continuation of07/981,751, which in turn is a continuation of Ser. No. 07/901,660 filedJun. 19, 1992, all of which are incorporated herein by reference. Ofcourse, the inner layer high acid ionomer compositions are not limitedin any way to those compositions set forth in said applications.

[0167] The high acid ionomers which may be suitable for use informulating the inner layer compositions are ionic copolymers which arethe metal, i.e., sodium, zinc, magnesium, etc., salts of the reactionproduct of an olefin having from about 2 to 8 carbon atoms and anunsaturated monocarboxylic acid having from about 3 to 8 carbon atoms.Preferably, the ionomeric resins are copolymers of ethylene and eitheracrylic or methacrylic acid. In some circumstances, an additionalcomonomer such as an acrylate ester (i.e., iso- or n-butylacrylate,etc.) can also be included to produce a softer terpolymer. Thecarboxylic acid groups of the copolymer are partially neutralized (i.e.,approximately 10-100%, preferably 30-70%) by the metal ions. Each of thehigh acid ionomer resins which may be included in the inner layer covercompositions of the invention contains greater than about 16% by weightof a carboxylic acid, preferably from about 17% to about 25% by weightof a carboxylic acid, more preferably from about 18.5% to about 21.5% byweight of a carboxylic acid.

[0168] Although the inner layer cover composition of several embodimentsof the present invention preferably includes a high acid ionomericresin, the scope of the patent embraces all known high acid ionomericresins falling within the parameters set forth above, only a relativelylimited number of these high acid ionomeric resins have recently becomecommercially available.

[0169] The high acid ionomeric resins available from Exxon under thedesignation “Escor™” and or “lotek”, are somewhat similar to the highacid ionomeric resins available under the “Surlyn™” trademark. However,since the Escor™/lotek ionomeric resins are sodium or zinc salts ofpoly(ethylene-acrylic acid) and the “Surlyn™” resins are zinc, sodium,magnesium, etc. salts of poly(ethylene-methacrylic acid), distinctdifferences in properties exist.

[0170] Examples of the high acid methacrylic acid based ionomers foundsuitable for use in accordance with this invention include Surlyn™ 8220and 8240 (both formerly known as forms of Surlyn™ AD-8422), Surlyn™ 9220(zinc cation), Surlyn™ SEP-503-1 (zinc cation), and Surlyn™ SEP-503-2(magnesium cation). According to DuPont, all of these ionomers containfrom about 18.5 to about 21.5% by weight methacrylic acid.

[0171] More particularly, Surlyn™ AD-8422 is currently commerciallyavailable from DuPont in a number of different grades (i.e., AD-8422-2,AD-8422-3, AD-8422-5, etc.) based upon differences in melt index.According to DuPont, Surlyn™ 8422, which is believed recently to havebeen redesignated as 8220 and 8240, offers the following generalproperties when compared to Surlyn™ 8920, the stiffest, hardest of allon the low acid grades (referred to as “hard” ionomers in U.S. Pat. No.4,884,814): LOW ACID HIGH ACID (15 wt % Acid) (>20 wt % Acid) SURLYN ™SURLYN ™ SURLYN ™ 8920 8422-2 8422-3 IONOMER Cation Na Na Na Melt Index1.2 2.8 1.0 Sodium, Wt % 2.3 1.9 2.4 Base Resin MI 60 60 60 MP¹, ° C. 8886 85 FP¹, ° C. 47 48.5 45 COMPRESSION MOLDING² Tensile Break, 4350 41905330 psi Yield, psi 2880 3670 3590 Elongation, % 315 263 289 Flex Mod,53.2 76.4 88.3 K psi Shore D 66 67 68 hardness

[0172] In comparing Surlyn™ 8920 to Surlyn™ 8422-2 and Surlyn™ 8422-3,it is noted that the high acid Surlyn™ 8422-2 and 8422-3 ionomers have ahigher tensile yield, lower elongation, slightly higher Shore D hardnessand much higher flexural modulus. Surlyn™ 8920 contains 15 weightpercent methacrylic acid and is 59% neutralized with sodium.

[0173] In addition, Surlyn™ SEP-503-1 (zinc cation) and Surlyn™SEP-503-2 (magnesium cation) are high acid zinc and magnesium versionsof the Surlyn™ AD 8422 high acid ionomers. When compared to the Surlyn™AD 8422 high acid ionomers, the Surlyn™ SEP-503-1 and SEP-503-2 ionomerscan be defined as follows: Surlyn ™ Ionomer Ion Melt IndexNeutralization % AD 8422-3 Na 1.0 45 SEP 503-1 Zn 0.8 38 SEP 503-2 Mg1.8 43

[0174] Further, Surlyn™ 8162 is a zinc cation ionomer resin containingapproximately 20% by weight (i.e., 18.5-21.5% weight) methacrylic acidcopolymer that has been 30-70% neutralized. Surlyn™ 8162 is currentlycommercially available from DuPont.

[0175] Examples of the high acid acrylic acid based ionomers suitablefor use in the present invention also include the Escor™ or lotek highacid ethylene acrylic acid ionomers produced by Exxon such as Ex 1001,1002, 959, 960, 989, 990, 1003, 1004, 993, 994. In this regard, Escor™or lotek 959 is a sodium ion neutralized ethylene-acrylic neutralizedethylene-acrylic acid copolymer. According to Exxon, loteks 959 and 960contain from about 19.0 to 21.0% by weight acrylic acid withapproximately 30 to about 70 percent of the acid groups neutralized withsodium and zinc ions, respectively. The physical properties of thesehigh acid acrylic acid based ionomers are set forth in Tables 3 and 4 asfollows: TABLE 3 Physical Properties of Various Ionomers ESCOR ™ ESCOR ™(IOTEK) (IOTEK) PROPERTY Ex1001 Ex1002 959 Ex1003 Ex1004 960 Melt index,1.0 1.6 2.0 1.1 2.0 1.8 g/10 min Cation Na Na Na Zn Zn Zn Melting 183183 172 180 180.5 174 Point, ° F. Vicat 125 125 130 133 131 131Softening Point, ° F. Tensile 34.4 MPa 22.5 MPa   4600 psi 24.8 MPa 20.6MPa   3500 psi @ Break Elongation 341 348 325 387 437 430 @ Break, %Hardness, 63 62 66 54 53 57 Shore D Flexural  365 MPa  380 MPa 66,000psi  147 MPa  130 MPa 27,000 psi Modulus

[0176] TABLE 4 Physical Properties of Various Ionomers EX 989 EX 993 EX994 EX 990 Melt index g/10 min 1.30 1.25 1.32 1.24 Moisture ppm 482 214997 654 Cation type — Na Li K Zn M+ content by AAS wt % 2.74 0.87 4.54 0Zn content by AAS wt % 0 0 0 3.16 Density kg/m³ 959 945 976 977 Vicatsoftening point ° C. 52.5 51 50 55.0 Crystallization point ° C. 40.139.8 44.9 54.4 Melting point ° C. 82.6 81.0 80.4 81.0 Tensile at yieldMPa 23.8 24.6 22 16.5 Tensile at break MPa 32.3 31.1 29.7 23.8Elongation at break % 330 260 340 357 1% secant modulus MPa 389 379 312205 Flexural modulus MPa 340 368 303 183 Abrasion resistance mg 20.0 9.215.2 20.5 Hardness Shore D — 62 62.5 61 56 Zwick Rebound % 61 63 59 48

[0177] Furthermore, as a result of the development by the assignee ofthis application of a number of new high acid ionomers neutralized tovarious extents by several different types of metal cations, such as bymanganese, lithium, potassium, calcium and nickel cations, several newhigh acid ionomers and/or high acid ionomer blends besides sodium, zincand magnesium high acid ionomers or ionomer blends are now available forgolf ball cover production. It has been found that these new cationneutralized high acid ionomer blends produce inner cover layercompositions exhibiting enhanced hardness and resilience due tosynergies which occur during processing. Consequently, the metal cationneutralized high acid ionomer resins recently produced can be blended toproduce substantially higher C.O.R.'s than those produced by the lowacid ionomer inner cover compositions presently commercially available.

[0178] More particularly, several new metal cation neutralized high acidionomer resins have been produced by the assignee by neutralizing, tovarious extents, high acid copolymers of an alpha-olefin and an alpha,beta-unsaturated carboxylic acid with a wide variety of different metalcation salts. This discovery is the subject matter of U.S. Pat. No.5,688,869, incorporated herein by reference. It has been found thatnumerous new metal cation neutralized high acid ionomer resins can beobtained by reacting a high acid copolymer (i.e., a copolymer containinggreater than 16% by weight acid, preferably from about 17 to about 25weight percent acid, and more preferably about 20 weight percent acid),with a metal cation salt capable of ionizing or neutralizing thecopolymer to the extent desired (i.e., from about 10% to 90%).

[0179] The base copolymer is made up of greater than 16% by weight of analpha, beta-unsaturated carboxylic acid and an alpha-olefin. Optionally,a softening comonomer can be included in the copolymer. Generally, thealpha-olefin has from 2 to 10 carbon atoms and is preferably ethylene,and the unsaturated carboxylic acid is a carboxylic acid having fromabout 3 to 8 carbons. Examples of such acids include acrylic acid,methacrylic acid, ethacrylic acid, chloroacrylic acid, crotonic acid,maleic acid, fumaric acid, and itaconic acid, with acrylic acid beingpreferred.

[0180] The softening comonomer that can be optionally included in theinner cover layer for the golf ball of the invention may be selectedfrom the group consisting of vinyl esters of aliphatic carboxylic acidswherein the acids have 2 to 10 carbon atoms, vinyl ethers wherein thealkyl groups contains 1 to 10 carbon atoms, and alkyl acrylates ormethacrylates wherein the alkyl group contains 1 to 10 carbon atoms.Suitable softening comonomers include vinyl acetate, methyl acrylate,methyl methacrylate, ethyl acrylate, ethyl methacrylate, butyl acrylate,butyl methacrylate, or the like.

[0181] Consequently, examples of a number of copolymers suitable for useto produce the high acid ionomers included in the present inventioninclude, but are not limited to, high acid embodiments of anethylene/acrylic acid copolymer, an ethylene/methacrylic acid copolymer,an ethylene/itaconic acid copolymer, an ethylene/maleic acid copolymer,an ethylene/methacrylic acid/vinyl acetate copolymer, anethylene/acrylic acid/vinyl alcohol copolymer, etc. The base copolymerbroadly contains greater than 16% by weight unsaturated carboxylic acid,from about 39 to about 83% by weight ethylene and from 0 to about 40% byweight of a softening comonomer. Preferably, the copolymer containsabout 20% by weight unsaturated carboxylic acid and about 80% by weightethylene. Most preferably, the copolymer contains about 20% acrylic acidwith the remainder being ethylene.

[0182] Along these lines, examples of the preferred high acid basecopolymers which fulfill the criteria set forth above, are a series ofethylene-acrylic copolymers which are commercially available from TheDow Chemical Company, Midland, Mich., under the “Primacor™” designation.These high acid base copolymers exhibit the typical properties set forthbelow in Table 5. TABLE 5 Typical Properties of PrimacorEthylene-Acrylic Acid Copolymers FLEXURAL PERCENT DENSITY, MELT INDEX,TENSILE MODULUS VICAT SHORE D GRADE ACID glcc g/10 min YD. ST (psi)(psi) SOFT PT (° C.) HARDNESS ASTM D-792 D-1238 D-638 D-790 D-1525D-2240 5980 20.0 0.958 300.0 — 4800 43 50 5990 20.0 0.955 1300.0 6502600-3200 40 42 5981 20.0 0.960 300.0 900 3200 46 48 5983 20.0 0.958500.0 850 3100 44 45 5991 20.0 0.953 2600.0 635 2600 38 40

[0183] Due to the high molecular weight of the Primacor 5981 grade ofthe ethylene-acrylic acid copolymer, this copolymer is the morepreferred grade utilized in the invention.

[0184] The metal cation salts utilized in the invention are those saltswhich provide the metal cations capable of neutralizing, to variousextents, the carboxylic acid groups of the high acid copolymer. Theseinclude acetate, oxide or hydroxide salts of lithium, calcium, zinc,sodium, potassium, nickel, magnesium, and manganese.

[0185] Examples of such lithium ion sources are lithium hydroxidemonohydrate, lithium hydroxide, lithium oxide and lithium acetate.Sources for the calcium include calcium hydroxide, calcium acetate andcalcium oxide. suitable zinc ion sources are zinc acetate dihydrate and,zinc acetate, a blend of zinc oxide and acetic acid. Examples of sodiumion sources are sodium hydroxide and sodium acetate. Sources for thepotassium ion include potassium hydroxide and potassium acetate.Suitable nickel ion sources are nickel acetate, nickel oxide and nickelhydroxide sources of magnesium include magnesium oxide, magnesiumhydroxide, magnesium acetate. Sources of manganese include manganeseacetate and manganese oxide.

[0186] The new metal cation neutralized high acid ionomer resins areproduced by reacting the high acid base copolymer with various amountsof the metal cation salts above the crystalline melting point of thecopolymer, such as at a temperature from about 200° F. to about 500° F.,preferably from about 250° F. to about 350° F., under high shearconditions at a pressure of from about 10 psi to 10,000 psi. Other wellknown blending techniques may also be used. The amount of metal cationsalt utilized to produce the new metal cation neutralized high acidbased ionomer resins is the quantity which provides a sufficient amountof the metal cations to neutralize the desired percentage of thecarboxylic acid groups in the high acid copolymer. The extent ofneutralization is generally from about 10% to about 90%.

[0187] As indicated below in Table 6 and more specifically in Example 1in U.S. application Ser. No. 08/493,089, a number of new types of metalcation neutralized high acid ionomers can be obtained from the aboveindicated process. These include new high acid ionomer resinsneutralized to various extends with manganese, lithium, potassium,calcium and nickel cations. In addition, when a high acidethylene/acrylic acid copolymer is utilized as the base copolymercomponent of the invention and this component is subsequentlyneutralized to various extents with the metal cation salts producingacrylic acid based high acid ionomer resins neutralized with cationssuch as sodium, potassium, lithium, zinc, magnesium, manganese, calciumand nickel, several new cation neutralized acrylic acid based high acidionomer resins are produced. TABLE 6 Metal Cation Neutralized High AcidIonomers Formulation Wt - % Wt - % Melt Shore D No. Cation SaltNeutralization Index C.O.R. Hardness 1(NaOH) 6.98 67.5 0.9 0.804 712(NaOH) 5.66 54 2.4 0.808 73 3(NaOH) 3.84 35.9 12.2 0.812 69 4(NaOH)2.91 27 17.5 0.812 (brittle) 5(MnAc) 19.6 71.7 7.5 0.809 73 6(MnAc) 23.188.3 3.5 0.814 77 7(MnAc) 15.3 53 7.5 0.81 72 8(MnAc) 26.5 106 0.7 0.813(brittle) 9(LiOH) 4.54 71.3 0.6 0.81 74 10(LiOH) 3.38 52.5 4.2 0.818 7211(LiOH) 2.34 35.9 18.6 0.815 72 12(KOH) 5.3 36 19.3 Broke 70 13(KOH)8.26 57.9 7.18 0.804 70 14(KOH) 10.7 77 4.3 0.801 67 15(ZnAc) 17.9 71.50.2 0.806 71 16(ZnAc) 13.9 53 0.9 0.797 69 17(ZnAc) 9.91 36.1 3.4 0.79367 18(MgAc) 17.4 70.7 2.8 0.814 74 19(MgAc) 20.6 87.1 1.5 0.815 7620(MgAc) 13.8 53.8 4.1 0.814 74 21(CaAc) 13.2 69.2 1.1 0.813 74 22(CaAc)7.12 34.9 10.1 0.808 70 23(MgO) 2.91 53.5 2.5 0.813 24(MgO) 3.85 71.52.8 0.808 25(MgO) 4.76 89.3 1.1 0.809 26(MgO) 1.96 35.7 7.5 0.81527(NiAc) 13.04 61.1 0.2 0.802 71 28(NiAc) 10.71 48.9 0.5 0.799 7229(NiAc) 8.26 36.7 1.8 0.796 69 30(NiAc) 5.66 24.4 7.5 0.786 64

[0188] When compared to low acid versions of similar cation neutralizedionomer resins, the new metal cation neutralized high acid ionomerresins exhibit enhanced hardness, modulus and resiliencecharacteristics. These are properties that are particularly desirable ina number of thermoplastic fields, including the field of golf ballmanufacturing.

[0189] When utilized in the construction of the inner layer of amulti-layered golf ball, it has been found that the new acrylic acidbased high acid ionomers extend the range of hardness beyond thatpreviously obtainable while maintaining the beneficial properties (i.e.durability, click, feel, etc.) of the softer low acid ionomer coveredballs, such as balls produced utilizing the low acid ionomers disclosedin U.S. Pat. Nos. 4,884,814 and 4,911,451.

[0190] Moreover, as a result of the development of a number of newacrylic acid based high acid ionomer resins neutralized to variousextents by several different types of metal cations, such as manganese,lithium, potassium, calcium and nickel cations, several new ionomers orionomer blends are now available for production of an inner cover layerof a multi-layered golf ball. By using these high, acid ionomer resins,harder, stiffer inner cover layers having higher C.O.R.s, and thuslonger distance, can be obtained.

[0191] More preferably, it has been found that when two or more of theabove-indicated high acid ionomers, particularly blends of sodium andzinc high acid ionomers, are processed to produce the covers ofmulti-layered golf balls, (i.e., the inner cover layer herein) theresulting golf balls will travel further than previously knownmulti-layered golf balls produced with low acid ionomer resin covers dueto the balls' enhanced coefficient of restitution values.

[0192] The low acid ionomers which may be suitable for use informulating the inner layer compositions of several of the embodimentsof the subject invention are ionic copolymers which are the metal, i.e.,sodium, zinc, magnesium, etc., salts of the reaction product of anolefin having from about 2 to 8 carbon atoms and an unsaturatedmonocarboxylic acid having from about 3 to 8 carbon atoms. Preferably,the ionomeric resins are copolymers of ethylene and either acrylic ormethacrylic acid. In some circumstances, an additional comonomer such asan acrylate ester (i.e., iso- or n-butylacrylate, etc.) can also beincluded to produce a softer terpolymer. The carboxylic acid groups ofthe copolymer are neutralized or partially neutralized (i.e.,approximately 10-100%, preferably 30-70%) by the metal ions. Each of thelow acid ionomer resins which may be included in the inner layer covercompositions of the invention contains 16% by weight or less of acarboxylic acid.

[0193] The inner layer compositions include the low acid ionomers suchas those developed and sold by E. I. DuPont de Nemours & Company underthe trademark “Surlyn™” and by Exxon Corporation under the trademark“Escor™” or tradename “lotek,” or blends thereof.

[0194] The low acid ionomer resins available from Exxon under thedesignation “Escor™” and/or “lotek,” are somewhat similar to the lowacid ionomeric resins available under the “Surlyn™” trademark. However,since the Escor™/lotek ionomeric resins are sodium or zinc salts ofpoly(ethylene-acrylic acid) and the “Surlyn™” resins are zinc, sodium,magnesium, etc. salts of poly(ethylene-methacrylic acid), distinctdifferences in properties exist.

[0195] When utilized in the construction of the inner layer of amulti-layered golf ball, it has been found that the low acid ionomerblends extend the range of compression and spin rates beyond thatpreviously obtainable. More preferably, it has been found that when twoor more low acid ionomers, particularly blends of sodium and zincionomers, are processed to produce the covers of multi-layered golfballs, (i.e., the inner cover layer herein) the resulting golf ballswill travel further and at an enhanced spin rate than previously knownmulti-layered golf balls. Such an improvement is particularly noticeablein enlarged or oversized golf balls.

[0196] The use of an inner layer formulated from blends of lower acidionomers produces multi-layer golf balls having enhanced compression andspin rates. These are the properties desired by the more skilled golfer.

[0197] In yet another embodiment of the inner cover layer, a blend ofhigh and low acid ionomer resins is used. These can be the ionomerresins described above, combined in a weight ratio which preferably iswithin the range of 10:90 to 90:10 parts of high and low acid ionomerresins.

[0198] A further additional embodiment of the inner cover layer isprimarily based upon the use of a fully non-ionomeric thermoplasticmaterial. Suitable non-ionomeric materials include metallocene catalyzedpolyolefins or polyamides, polyamide/ionomer blends, polyphenyleneether/ionomer blends, etc., which have a shore D hardness of 60 and aflex modulus of greater than about 30,000 psi, or other hardness andflex modulus values which are comparable to the properties of theionomers described above. Other suitable materials include but are notlimited to thermoplastic or thermosetting polyurethanes, a polyesterelastomer such as that marketed by DuPont under the trademark Hytrel™(polyether ester), or a polyether amide such as that marketed by ElfAtochem S.A. under the trademark Pebax™, a blend of two or morenon-ionomeric thermoplastic elastomers, or a blend of one or moreionomers and one or more non-ionomeric thermoplastic elastomers.

[0199] ii. Outer Cover Layer

[0200] While the dual core component described below, and the hard innercover layer formed thereon, provide the multi-layer golf ball with powerand distance, the outer cover layer 16 is comparatively softer than theinner cover layer. The softness provides for the feel and playabilitycharacteristics typically associated with balata or balata-blend balls.The outer cover layer or ply is comprised of a relatively soft, lowmodulus (about 1,000 psi to about 10,100 psi) and, in an alternateembodiment, low acid (less than 16 weight percent acid) ionomer, anionomer blend, a non-ionomeric thermoplastic or thermosetting materialsuch as, but not limited to, a metallocene catalyzed polyolefin such asEXACT™ material available from EXXON™ a polyurethane, a polyesterelastomer such as that marketed by DuPont under the trademark Hytrel™,or a polyether amide such as that marketed by Elf Atochem S.A. under thetrademark Pebax™, a blend of two or more non-ionomeric thermoplastic orthermosetting materials, or a blend of one or more ionomers and one ormore non-ionomeric thermoplastic materials.

[0201] The outer layer is fairly thin (i.e. from about 0.010 to about0.10 inches in thickness, more desirably 0.03 to 0.06 inches inthickness for a 1.680 inch ball and 0.03 to 0.06 inches in thickness fora 1.72 inch or more ball), but thick enough to achieve desiredplayability characteristics while minimizing expense. Thickness isdefined as the average thickness of the non-dimpled areas of the outercover layer. The outer cover layer, such as layer 16, has a Shore Dhardness of at least 1 point softer than the inner cover or Shore D of57 or less.

[0202] In one embodiment, the outer cover layer preferably is formedfrom an ionomer which constitutes at least 75 weight % of an acrylateester-containing ionic copolymer or blend of acrylate ester-containingionic copolymers. This type of outer cover layer in combination with thecore and inner cover layer described above results in golf ball covershaving a favorable combination of durability and spin rate. The one ormore acrylate ester-containing ionic copolymers each contain an olefin,an acrylate ester, and an acid. In a blend of two or more acrylateester-containing ionic copolymers, each copolymer may contain the sameor a different olefin, acrylate ester and acid than are contained in theother copolymers. Preferably, the acrylate ester-containing ioniccopolymer or copolymers are terpolymers, but additional monomers can becombined into the copolymers if the monomers do not substantially reducethe scuff resistance or other good playability properties of the cover.

[0203] For a given copolymer, the olefin is selected from the groupconsisting of olefins having 2 to 8 carbon atoms, including, asnon-limiting examples, ethylene, propylene, butene-1, hexene-1 and thelike. Preferably the olefin is ethylene.

[0204] The acrylate ester is an unsaturated monomer having from 1 to 21carbon atoms which serves as a softening comonomer. The acrylate esterpreferably is methyl, ethyl, n-propyl, n-butyl, n-octyl, 2-ethylhexyl,or 2-methoxyethyl 1-acrylate, and most preferably is methyl acrylate orn-butyl acrylate. Another suitable type of softening comonomer is analkyl vinyl ether selected from the group consisting of n-butyl,n-hexyl, 2-ethylhexyl, and 2-methoxyethyl vinyl ethers.

[0205] The acid is a mono- or dicarboxylic acid and preferably isselected from the group consisting of methacrylic, acrylic, ethacrylic,α-chloroacrylic, crotonic, maleic, fumaric, and itaconic acid, or thelike, and half esters of maleic, fumaric and itaconic acid, or the like.The acid group of the copolymer is 10-100% neutralized with any suitablecation, for example, zinc, sodium, magnesium, lithium, potassium,calcium, manganese, nickel, chromium, tin, aluminum, or the like. It hasbeen found that particularly good results are obtained when theneutralization level is about 50100%.

[0206] The one or more acrylate ester-containing ionic copolymers eachhas an individual Shore D hardness of about 5-64. The overall Shore Dhardness of the outer cover is 57 or less, and generally is 40-55. It ispreferred that the overall Shore D hardness of the outer cover is in therange of 40-50 in order to impart particularly good playabilitycharacteristics to the ball.

[0207] The outer cover layer of the invention is formed over a core toresult in a golf ball having a coefficient of restitution of at least0.760, more preferably at least 0.770, and most preferably at least0.780. The coefficient of restitution of the ball will depend upon theproperties of both the core and the cover. The PGA compression of thegolf ball is 100 or less, and preferably is 90 or less.

[0208] The acrylate ester-containing ionic copolymer or copolymers usedin the outer cover layer can be obtained by neutralizing commerciallyavailable acrylate ester-containing acid copolymers such aspolyethylene-methyl acrylate-acrylic acid terpolymers, including ESCOR™ATX (Exxon Chemical Company) or poly (ethylene-butylacrylate-methacrylic acid) terpolymers, including NUCREL™ (DuPontChemical Company). Particularly preferred commercially availablematerials include ATX 320, ATX 325, ATX 310, ATX 350, and blends ofthese materials with NUCREL™ 010 and NUCREL™ 035. The acid groups ofthese materials and blends are neutralized with one or more of variouscation salts including zinc, sodium, magnesium, lithium, potassium,calcium, manganese, nickel, etc. The degree of neutralization rangesfrom 10-100%. Generally, a higher degree of neutralization results in aharder and tougher cover material. The properties of non-limitingexamples of commercially available un-neutralized acid terpolymers whichcan be used to form the golf ball outer cover layers of the inventionare provided below in Table 7. TABLE 7 Properties of Un-Neutralized AcidTerpolymers Flex Melt Index Modulus dg/min Acid No. MPa Hardness TradeName ASTM D 1238 % KOH/g (ASTM D790) (Shore D) ATX 310 6 45 80 44 ATX320 5 45 50 34 ATX 325 20 45 9 30 ATX 350 6 15 20 28 Nucrel ™ 010 11 6040 40 Nucrel ™ 035 35 60 59 40

[0209] The ionomer resins used to form the outer cover layers can beproduced by reacting the acrylate ester-containing acid copolymer withvarious amounts of the metal cation salts at a temperature above thecrystalline melting point of the copolymer, such as a temperature fromabout 20⁰° F. to about 500° F., preferably from about 250° F. to about350° F., under high shear conditions at a pressure of from about 100 psito 10,000 psi. Other well known blending techniques may also be used.The amount of metal cation salt utilized to produce the neutralizedionic copolymers is the quantity which provides a sufficient amount ofthe metal cations to neutralize the desired percentage of the carboxylicacid groups in the high acid copolymer. When two or more differentcopolymers are to be used, the copolymers can be blended before or afterneutralization. Generally, it is preferable to blend the copolymersbefore they are neutralized to provide for optimal mixing.

[0210] The compatibility of the acrylate ester-containing copolymerswith each other in a copolymer blend produces a golf ball outer coverlayer having a surprisingly good scuff resistance for a given hardnessof the outer cover layer. The golf ball according to the invention has ascuff resistance of no higher than 3.0. It is preferred that the golfball has a scuff resistance of no higher than about 2.5 to ensure thatthe golf ball is scuff resistant when used in conjunction with a varietyof types of clubs, including sharp-grooved irons, which are particularlyinclined to result in scuffing of golf ball covers. The best resultsaccording to the invention are obtained when the outer cover layer has ascuff resistance of no more than about 2.0.

[0211] Additional materials may also be added to the inner and outercover layer of the present invention as long as they do notsubstantially reduce the playability properties of the ball. Suchmaterials include dyes (for example, Ultramarine Blue™ sold by Whitaker,Clark, and Daniels of South Plainsfield, N.J.) (see U.S. Pat. No.4,679,795), pigments such as titanium dioxide, zinc oxide, bariumsulfate and zinc sulfate; UV absorbers; optical brighteners such asEastobrite™ OB-1 and Uvitex™ OB antioxidants; antistatic agents; andstabilizers. Moreover, the cover compositions of the present inventionmay also contain softening agents such as those disclosed in U.S. Pat.Nos. 5,312,857 and 5,306,760, including plasticizers, metal stearates,processing acids, etc., and reinforcing materials such as glass fibersand inorganic fillers, as long as the desired properties produced by thegolf ball covers of the invention are not impaired.

[0212] The outer layer in another embodiment of the invention includes ablend of a soft (low acid) ionomer resin with a small amount of a hard(high acid) ionomer resin. A low modulus ionomer suitable for use in theouter layer blend has a flexural modulus measuring from about 1,000 toabout 10,000 psi, with a hardness of about 20 to about 40 on the Shore Dscale. A high modulus ionomer herein is one which measures from about15,000 to about 70,000 psi as measured in accordance with ASTM methodD-790. The hardness may be defined as at least 50 on the Shore D scaleas measured in accordance with ASTM method D-2240, but on the ball andnot on a plaque.

[0213] Soft ionomers primarily are used in formulating the hard/softblends of the cover compositions. These ionomers include acrylic acidand methacrylic acid based soft ionomers. They are generallycharacterized as comprising sodium, zinc, or other mono- or divalentmetal cation salts of a terpolymer of an olefin having from about 2 to 8carbon atoms, methacrylic acid, acrylic acid, or another, α,β-unsaturated carboxylic acid, and an unsaturated monomer of theacrylate ester class having from 1 to 21 carbon atoms. The soft ionomeris preferably made from an acrylic acid base polymer is an unsaturatedmonomer of the acrylate ester class.

[0214] Certain ethylene-acrylic acid based soft ionomer resins developedby the Exxon Corporation under the designation “lotek 7520” (referred toexperimentally by differences in neutralization and melt indexes as LDX195, LDX 196, LDX 218 and LDX 219) may be combined with known hardionomers such as those indicated above to produce the inner and outercover layers. The combination produces higher C.O.R.s at equal or softerhardness, higher melt flow, (which corresponds to improved, moreefficient molding, i.e., fewer rejects) as well as significant costsavings versus the outer layer of multi-layer balls produced by otherknown hard-soft ionomer blends as a result of the lower overall rawmaterials cost and improved yields.

[0215] While the exact chemical composition of the resins to be sold byExxon under the designation lotek 7520 is considered by Exxon to beconfidential and proprietary information, Exxon's experimental productdata sheet lists the following physical properties of the ethyleneacrylic acid zinc ionomer developed by Exxon: TABLE 8 Property ValueASTM Method Units Typical Physical Properties of lotek 7520 Melt IndexD-1238 g/10 min. 2 Density D-1505 kg/m³ 0.962 Cation Zinc Melting PointD-3417 ° C. 66 Crystallization D-3417 ° C. 49 Point Vicat SofteningD-1525 ° C. 42 Point Plaque Properties (2 mm thick Compression MoldedPlaques) Tensile at Break D-638 MPa 10 Yield Point D-638 MPa NoneElongation at Break D-638 % 760 1% Secant Modulus D-638 MPa 22 Shore DHardness D-2240 32 Flexural Modulus D-790 MPa 26 Zwick Rebound ISO 4862% 52 De Mattia Flex D-430 Cycles >5000 Resistance

[0216] In addition, test data collected by the inventor indicates thatlotek 7520 resins have Shore D hardnesses of about 32 to 36 (per ASTMD-2240), melt flow indexes of 3″0.5 g/10 min (at 190° C. per ASTMD-1288), and a flexural modulus of about 2500-3500 psi (per ASTM D-790).Furthermore, testing by an independent testing laboratory by pyrolysismass spectrometry indicates at lotek 7520 resins are generally zincsalts of a terpolymer of ethylene, acrylic acid, and methyl acrylate.

[0217] Furthermore, the inventor has found that a newly developed gradeof an acrylic acid based soft ionomer available from the ExxonCorporation under the designation lotek 7510 is also effective whencombined with the hard ionomers indicated above in producing golf ballcovers exhibiting higher C.O.R. values at equal or softer hardness thanthose produced by known hard-soft ionomer blends. In this regard, lotek7510 has the advantages (i.e. improved flow, higher C.O.R. values atequal hardness, increased clarity, etc.) produced by the lotek 7520resin when compared to the methacrylic acid base soft ionomers known inthe art (such as the Surlyn™ 8625 and Surlyn™ 8629 combinationsdisclosed in U.S. Pat. No. 4,884,814).

[0218] In addition, lotek 7510, when compared to lotek 7520, producesslightly higher C.O.R. values at equal softness/hardness due to thelotek 7510's higher hardness and neutralization. Similarly, lotek 7510produces better release properties (from the mold cavities) due to itsslightly higher stiffness and lower flow rate than lotek 7520. This isimportant in production where the soft covered balls tend to have loweryields caused by sticking in the molds and subsequent punched pin marksfrom the knockouts.

[0219] According to Exxon, lotek 7510 is of similar chemical compositionas lotek 7520 (i.e. a zinc salt of a terpolymer of ethylene, acrylicacid, and methyl acrylate) but is more highly neutralized. Based uponFTIR analysis, lotek 7520 is estimated to be about 30-40 wt.-%neutralized and lotek 7510 is estimated to be about 40-60 wt.-%neutralized. The typical properties of lotek 7510 in comparison of thoseof lotek 7520 in comparison of those of lotek 7520 are set forth below:TABLE 9 Physical Properties of Iotek 7510 in Comparison to Iotek 7520IOTEK 7520 IOTEK 7510 MI, g/10 min 2.0 0.8 Density, g/cc 0.96 0.97Melting Point, ° F. 151 149 Vicat Softening Point, ° F. 108 109 FlexModulus, psi 3800 5300 Tensile Strength, psi 1450 1750 Elongation, % 760690 Hardness, Shore D 32 35

[0220] The hard ionomer resins utilized to produce the outer cover layercomposition hard/soft blends include ionic copolymers which are thesodium, zinc, magnesium, lithium, etc. salts of the reaction product ofan olefin having from 2 to 8 carbon atoms and an unsaturatedmonocarboxylic acid having from 3 to 8 carbon atoms. The carboxylic acidgroups of the copolymer may be totally or partially (i.e. approximately15-75 percent) neutralized.

[0221] The hard ionomeric resins are likely copolymers of ethylene andacrylic and/or methacrylic acid, with copolymers of ethylene and acrylicacid being the most preferred. Two or more types of hard ionomericresins may be blended into the outer cover layer compositions in orderto produce the desired properties of the resulting golf balls.

[0222] As discussed earlier herein, the hard ionomeric resins introducedunder the designation Escor™ and sold under the designation “lotek” aresomewhat similar to the hard ionomeric resins sold under the Surlyn™trademark. However, since the “lotek” ionomeric resins are sodium orzinc salts of poly(ethylene-acrylic acid) and the Surlyn™ resins arezinc or sodium salts of poly(ethylene-methacrylic acid) some distinctdifferences in properties exist. As more specifically indicated in thedata set forth below, the hard “lotek” resins (i.e., the acrylic acidbased hard ionomer resins) are the more preferred hard resins for use informulating the outer layer blends for use in the present invention. Inaddition, various blends of “lotek” and Surlyn™ hard ionomeric resins,as well as other available ionomeric resins, may be utilized in thepresent invention in a similar manner.

[0223] Examples of commercially available hard ionomeric resins whichmay be used in the present invention in formulating the outer coverblends include the hard sodium ionic copolymer sold under the trademark$urlyn™ 8940 and the hard zinc ionic copolymer sold under the trademarkSurlyn™ 9910. Surlyn™ 8940 is a copolymer of ethylene with methacrylicacid and about 15 weight percent acid which is about 29 percentneutralized with sodium ions. This resin has an average melt flow indexof about 2.8. Surlyn™ 9910 is a copolymer of ethylene and methacrylicacid with about 15 weight percent acid which is about 58 percentneutralized with zinc ions. The average melt flow index of Surlyn™ 9910is about 0.7. The typical properties of Surlyn™ 9910 and 8940 are setforth below in Table 10: TABLE 10 Typical Properties of CommerciallyAvailable Hard Surlyn ™ Resins Suitable for Use in the Outer LayerBlends of the Present Invention ASTM D 8940 9910 8920 8528 9970 9730Cation Type Sodium Zinc Sodium Sodium Zinc Zinc Melt flow index, D-12382.8 0.7 0.9 1.3 14.0 1.6 gms/10 min. Specific Gravity, D-792 0.95 0.970.95 0.94 0.95 0.95 g/cm³ Hardness, Shore D D-2240 66 64 66 60 62 63Tensile Strength, D-638 (4.8)  (3.6)  (5.4)  (4.2)  (3.2)  (4.1) (kpsi), MPa 33.1 24.8 37.2 29.0 22.0 28.0 Elongation, % D-638 470 290350 450 460 460 Flexural Modulus, D-790 (51)   (48)   (55)   (32)  (28)   (30)   (kpsi) MPa 350 330 380 220 190 210 Tensile Impact (23° C.)D-1822S 1020 1020 865 1160 760 1240 KJ/m₂ (ft.-lbs./in²) (485)  (485) (410)  (550)  (360)  (590)  Vicat Temperature, ° C. D-1525 63 62 58 7361 73

[0224] Examples of the more pertinent acrylic acid based hard ionomerresin suitable for use in the present outer cover composition sold underthe “lotek” trade name by the Exxon Corporation include lotek 8000,8010, 8020, 8030, 7030, 7010, 7020, 1002, 1003, 959 and 960. Thephysical properties of lotek 959 and 960 are shown above. The typicalproperties of the remainder of these and other lotek hard ionomerssuited for use in formulating the outer layer cover composition are setforth below in Table 11: TABLE 11 Typical Properties of Iotek IonomersASTM Method Units 4000 4010 8000 8020 8030 Resin Properties Cation typezinc zinc sodium sodium sodium Melt index D-1238 g/10 min 2.5 1.5 0.81.6 2.8 Density D-1505 kg/m³ 963 963 954 960 960 Melting Point D-3417 °C. 90 90 90 87.5 87.5 Crystallization D-3417 ° C. 62 64 56 53 55 PointVicat Softening D-1525 ° C. 62 63 61 64 67 Point % Weight Acrylic Acid16 15 % of Acid Groups 30 40 cation neutralized Plaque Properties (3 mmthick, compression molded) Tensile at break D-638 MPa 24 26 36 31.5 28Yield point D-638 MPa none none 21 21 23 Elongation at break D-638 % 395420 350 410 395 1% Secant modulus D-638 MPa 160 160 300 350 390 ShoreHardness D D-2240 — 55 55 61 58 59 Film Properties (50 micron film 2.2:1Blow-up ratio) Tensile at Break MD D-882 MPa 41 39 42 52 47.4 TD D-882MPa 37 38 38 38 40.5 Yield point MD D-882 MPa 15 17 17 23 21.6 TD D-882MPa 14 15 15 21 20.7 Elongation at Break MD D-882 % 310 270 260 295 305TD D-882 % 360 340 280 340 345 1% Secant modulus MD D-882 MPa 210 215390 380 380 TD D-882 MPa 200 225 380 350 345 Dart Drop Impact D-1709g/micron 12.4 12.5 20.3 ASTM Method Units 7010 7020 7030 ResinProperties Cation type zinc zinc zinc Melt Index D-1238 g/10 min. 0.81.5 2.5 Density D-1505 kg/m³ 960 960 960 Melting Point D-3417 NC 90 9090 Crystallization D-3417 NC — — — Point Vicat Softening D-1525 NC 60 6362.5 Point % Weight Acrylic Acid — — — % of Acid Groups — — — CationNeutralized Plaque Properties (3 mm thick, compression molded) Tensileat break D-638 MPa 38 38 38 Yield Point D-638 MPa none none noneElongation at break D-638 % 500 420 395 1% Secant modulus D-638 MPa — —— Shore Hardness D D-2240 — 57 55 55

[0225] It has been determined that when hard/soft ionomer blends areused for the outer cover layer, good results are achieved when therelative combination is in a range of about 3-25 percent hard ionomerand about 75-97 percent soft ionomer.

[0226] Moreover, in alternative embodiments, the outer cover layerformulation may also comprise up to 100 wt % of a soft, low modulusnon-ionomeric thermoplastic material including a polyester polyurethanesuch as B. F. Goodrich Company's Estane™ polyester polyurethane X-4517.The non-ionomeric thermoplastic material may be blended with a softionomer. For example, polyamides blend well with soft ionomer. Accordingto B.F. Goodrich, Estane™ X-4517 has the following properties:Properties of Estane ™ X-4517 Tensile 1430 100% 815 200% 1024 300% 1193Elongation 641 Youngs Modulus 1826 Hardness A/D 88/39 Bayshore Rebound59 Solubility in Water Insoluble Melt processing temperature >350NF(>177NC) 1.1-1.3 Specific Gravity (H₂O = 1)

[0227] Other soft, relatively low modulus non-ionomeric thermoplasticelastomers may also be utilized to produce the outer cover layer as longas the non-ionomeric thermoplastic elastomers produce the playabilityand durability characteristics desired without adversely effecting theenhanced travel distance characteristic produced by the high acidionomer resin composition. These include, but are not limited to,thermoplastic polyurethanes such as Texin™, thermoplastic polyurethanesfrom Mobay Chemical Co. and the Pellethane™ thermoplastic polyurethanesfrom Dow Chemical Co.; non-ionomeric thermoset polyurethanes includingbut not limited to those disclosed in U.S. Pat. No. 5,334,673;cross-linked metallocene catalyzed polyolefins; ionomer/rubber blendssuch as those in Applicants' U.S. Pat. Nos. 4,986,545; 5,098,105 and5,187,013; and, Hytrel™ polyester elastomers from DuPont and Pebax™polyetheramides from Elf Atochem S.A.

[0228] B. Single Layer Covers

[0229] The cores of the present invention can also be covered by asingle cover layer. Preferably, the single layer covers are comprised ofthe outer layer cover materials discussed above. Additionally, thesingle layer covers can also comprise the inner cover materialsreferenced above.

Method of Making Golf Ball

[0230] In preparing golf balls in accordance with the present invention,a cover layer is molded (by injection molding or by compression molding)about a core (a dual core).

[0231] The dual cores of the present invention are preferably formed bythe compression molding techniques set forth above. However, it is fullycontemplated that liquid injection molding or transfer moldingtechniques could also be utilized.

[0232] A relatively hard inner cover layer is then molded about theresulting dual core component. The diameter of the inner cover is about1.570 inches. A comparatively softer outer cover layer is then moldedabout the inner cover layer. The outer cover diameter is about 1.680inches. Details of molding the inner and outer covers are set forthherein. Alternatively, a single soft cover can be molded around the dualcore.

[0233] Generally, the inner cover layer which is molded over the dualcore component, is about 0.01 inches to about 0.10 inches in thickness,preferably about 0.03-0.07 inches thick. The inner ball which includesthe core and inner cover layer preferably has a diameter in the range of1.25 to 1.60 inches. The outer cover layer is about 0.01 inches to about0.10 inches in thickness. Together, the dual core, the inner cover layerand the outer cover layer combine to form a ball having a diameter of1.680 inches or more, the minimum diameter permitted by the rules of theUnited States Golf Association and weighing no more than 1.62 ounces.

[0234] Most preferably, the resulting golf balls in accordance with thepresent invention have the following dimensions: Size Specifications:Range Preferred Inner Core Max. 0.830″ 0.344″ Min. 0.200″ 0.340″ OuterCore Max. 1.60″ 1.595″ Min. 1.25″ 1.47″ Cover Thickness Max. 0.215″0.065″ Min. 0.040″ 0.040″

[0235] In a particularly preferred embodiment of the invention, the golfball has a dimple pattern which provides coverage of 60%-70% or more.The golf ball typically is coated with a durable, abrasion-resistant,relatively non-yellowing finish coat.

[0236] The various cover composition layers of the present invention maybe produced according to conventional melt blending procedures.Generally, the copolymer resins are blended in a Banbury™ type mixer,two-roll mill, or extruder prior to neutralization. After blending,neutralization then occurs in the melt or molten states in the Banbury™mixer. Mixing problems are minimal because preferably more than 75 wt %,and more preferably at least 80 wt % of the ionic copolymers in themixture contain acrylate esters and, in this respect, most of thepolymer chains in the mixture are similar to each other. The blendedcomposition is then formed into slabs, pellets, etc., and maintained insuch a state until molding is desired.

[0237] Alternatively, a simple dry blend of the pelletized or granulatedresins which have previously been neutralized to a desired extent andcolored masterbatch may be prepared and fed directly into the injectionmolding machine where homogenization occurs in the mixing section of thebarrel prior to injection into the mold. If necessary, further additivessuch as an inorganic filler, etc., may be added and uniformly mixedbefore initiation of the molding process. A similar process is utilizedto formulate the high acid ionomer resin compositions used to producethe inner cover layer. In one embodiment of the invention, a masterbatchof non-acrylate ester-containing ionomer with pigments and otheradditives incorporated therein is mixed with the acrylateester-containing copolymers in a ratio of about 1-7 weight % masterbatchand 93-99 weight % acrylate ester-containing copolymer. However, amasterbatch is generally not used commercially to form the inner coveror mantle layer due to cost concerns.

[0238] The golf balls of the present invention can also be produced bymolding processes which include but are not limited to those which arecurrently well known in the golf ball art. For example, the golf ballscan be produced by injection molding or compression molding the novelcover compositions around a solid molded core to

[0239] Golf balls according to the invention preferably have a PGAcompression of 10-120. In a particularly preferred form of theinvention, the golf balls have a PGA compression of about 40-100. It hasbeen found that excellent results are obtained when the PGA compressionof the golf balls is 60-100. The coefficient of restitution of the golfballs of the invention is in the range of 0.770 or greater. Preferably,the C.O.R. of the golf balls is in the range of 0.770-0.830 and mostpreferably 0.790-0.830.

[0240] As mentioned above, resiliency and compression are amongst theprincipal properties involved in a golf ball's performance. In the past,PGA compression related to a scale of 0 to 200 given to a golf ball. Thelower the PGA compression value, the softer the feel of the ball uponstriking. In practice, tournament quality balls have compression ratingsaround 70-110, preferably around 80 to 100.

[0241] In determining PGA compression using the 0-200 scale, a standardforce is applied to the external surface of the ball. A ball whichexhibits no deflection (0.0 inches in deflection) is rated 200 and aball which deflects {fraction (2/10)}th of an inch (0.2 inches) is rated0. Every change of 0.001 of an inch in deflection represents a 1 pointdrop in compression. Consequently, a ball which deflects 0.1 inches(100×0.001 inches) has a PGA compression value of 100 (i.e., 200-100)and a ball which deflects 0.110 inches (110×0.001 inches) has a PGAcompression of 90 (i.e., 200-110).

[0242] In order to assist in the determination of compression, severaldevices have been employed by the industry. For example, PGA compressionin determined by an apparatus fashioned in the form of a small presswith an upper and lower anvil. The upper anvil is at rest against a diespring, and the lower anvil is movable through 0.300 inches by means ofa crank mechanism. In its open position the gap between the anvils is1.780 inches allowing a clearance of 0.100 inches for insertion of theball. As the lower anvil is raised by the crank, it compresses the ballagainst the upper anvil, such compression occurring during the last0.200 inches of stroke of the lower anvil, the ball then loading theupper anvil which in turn loads the spring. The equilibrium point of theupper anvil is measured by a dial micrometer if the anvil is deflectedby the ball more than 0.100 inches (less deflection is simply regardedas produce an inner ball which typically has a diameter of about 1.25 to1.60 inches. The core, preferably of a dual core configuration, may beformed as previously described. The outer layer is subsequently moldedover the inner layer to produce a golf ball having a diameter ofpreferably about 1.680 inches or more.

[0243] In compression molding, the inner cover composition is formed viainjection at about 380° F. to about 450° F. into smooth surfacedhemispherical shells which are then positioned around the core in a moldhaving the desired inner cover thickness and subjected to compressionmolding at 200° F. to 300° F. for about 2 to 10 minutes, followed bycooling at 50° F. to 70° F. for about 2 to 7 minutes to fuse the shellstogether to form a unitary intermediate ball. In addition, theintermediate balls may be produced by injection molding wherein theinner cover layer is injected directly around the core placed at thecenter of an intermediate ball mold for a period of time in a moldtemperature of from 50° F. to about 100° F. Subsequently, the outercover layer is molded around the core and the inner layer by similarcompression or injection molding techniques to form a dimpled golf ballof a diameter of 1.680 inches or more.

[0244] After formation of the balls, the balls are optionally subjectedto gamma radiation. This has been found to crosslink the cover toimprove scuff and cut resistance. Furthermore, the gamma radiation hasalso been found to increase the crosslink density of the core andresults in a harder and higher compression core and ball. And so, theShore C hardness of the core typically increases after gamma treatment.

[0245] After molding and/or radiation treatment, the golf balls producedmay undergo various further processing steps such as buffing, paintingand marking as disclosed in U.S. Pat. No. 4,911,451.

[0246] The resulting golf ball produced from the hard inner layer andthe relatively softer, low flexural modulus outer layer provide for animproved multi-layer golf ball having a unique dual core configurationwhich provides for desirable coefficient of restitution and durabilityproperties while at the same time offering the feel and spincharacteristics associated with soft balata and balata-like covers ofthe prior art. zero compression) and the reading on the micrometer dialis referred to as the compression of the ball. In practice, tournamentquality balls have compression ratings around 80 to 100 which means thatthe upper anvil was deflected a total of 0.120 to 0.100 inches.

[0247] An example to determine PGA compression can be shown by utilizinga golf ball compression tester produced by Atti Engineering Corporationof Newark, N.J., now manufactured by OK Automation of Sinking Spring,Pa. The value obtained by this tester relates to an arbitrary valueexpressed by a number which may range from 0 to 100, although a value of200 can be measured as indicated by two revolutions of the dialindicator on the apparatus. The value obtained defines the deflectionthat a golf ball undergoes when subjected to compressive loading. TheAtti test apparatus consists of a lower movable platform and an uppermovable spring-loaded anvil. The dial indicator is mounted such that itmeasures the upward movement of the spring loaded anvil. The golf ballto be tested is placed in the lower platform, which is then raised afixed distance. The upper portion of the golf ball comes in contact withand exerts a pressure on the springloaded anvil. Depending upon thedistance of the golf ball to be compressed, the upper anvil is forcedupward against the spring.

[0248] Alternative devices have also been employed to determinecompression. For example, Applicants also utilize a modified RiehleCompression Machine originally produced by Riehle Bros. Testing MachineCompany, Phil., PA to evaluate compression of the various components(i.e., cores, mantle cover balls, finished balls, etc.) of the golfballs. The Riehle compression device determines deformation inthousandths of an inch under a load designed to emulate the forceapplied by the Atti or PGA compression tester. Using such a device, aRiehle compression of 61 corresponds to a deflection under load of 0.061inches.

[0249] Additionally, an approximate relationship between Riehlecompression and PGA compression exists for balls of the same size. Ithas been determined by Applicants that Riehle compression corresponds toPGA compression by the general formula PGA compression=160−Riehlecompression. Consequently, 80 Riehle compression corresponds to 80 PGAcompression, 70 Riehle corresponds to 90 PGA compression, and 60 PGAcompression corresponds to 100 PGA compression. For reporting purposes,Applicants' compression values are usually measured as Riehlecompression and converted to PGA compression.

[0250] Furthermore, additional compression devices may also be utilizedto monitor golf ball compression so long as the correlation to PGAcompression is known. These devices have been designed, such as aWhitney Tester, to correlate or correspond to PGA compression through aset relationship or formula.

[0251] As used herein, “Shore D hardness” or “Shore C hardness” of acore or cover component is measured generally in accordance with ASTMD-2240, except the measurements are made on the curved surface of themolded component, rather than on a plaque. Furthermore, the Shore C-Dhardness of the cover is measured while the cover remains over the core.When a hardness measurement is made on a dimpled cover, Shore C-Dhardness is measured at a land area of the dimpled cover.

[0252] Golf balls according to the invention have a cut resistance inthe range of 1-3 on a scale of 1-5. It is preferred that the golf ballsof the invention have a cut resistance of 1-2.5 and most preferably 1-2.

[0253] The scuff resistance test was conducted in the following manner:a Top-Flite™ Tour pitching wedge (1994) with box grooves was obtainedand was mounted in a Miyamae™ driving machine. The club face wasoriented for a square hit. The forward/backward tee position wasadjusted so that the tee was four inches behind the point in thedownswing where the club was vertical. The height of the tee and thetoe-heel position of the club relative to the tee were adjusted in orderthat the center of the impact mark was about 3/4 of an inch above thesole and was centered toe to heel across the face. The machine wasoperated at a clubhead speed of 125 feet per second. Three samples ofeach ball were tested. Each ball was hit three times. After testing, theballs were rated according to the following table: Rating Type of damage1 Little or no damage (groove markings or dents) 2 Small cuts and/orripples in cover 3 Moderate amount of material lifted from ball surfacebut still attached to ball 4 Material removed or barely attached

[0254] Cut resistance was measured in accordance with the followingprocedure: A golf ball was fired at 135 feet per second against theleading edge of a 1994 Top-Flite™ Tour pitching wedge, wherein theleading edge radius is {fraction (1/32)} inch, the loft angle is 51degrees, the sole radius is 2.5 inches, and the bounce angle is 7degrees. The cut resistance of the balls tested herein was evaluated ona scale of 1-5. A 5 represents a cut that extends completely through thecover to the Core; a 4 represents a cut that does not extend completelythrough the cover but that does break the surface; a 3 does not breakthe surface of the cover but does leave a permanent dent; a 2 leavesonly a slight crease which is permanent but not as severe as 3; and a 1represents virtually no visible indentation or damage of any sort.

[0255] The spin rate of the ball of the invention may be tested in themanner described in Example 2 below.

[0256] Having generally described the invention, the following examplesare included for purposes of illustration so that the invention may bemore readily understood and are in no way intended to limit the scope ofthe invention unless otherwise specifically indicated.

EXAMPLES Example 1 Dual Core Golf Ball With Heavy Elastomeric NucleusComprising a Tungsten Powder/Polybutadiene Rubber Core, {fraction(11/32)}″ Diameter

[0257] 1A. A Dual Core and a Dual Cover Golf Ball

[0258] A heavy spherical center core layer containing powdered tungstenmetal in a polybutadiene matrix and having a diameter of 0.344 inches(8.74 mm) was formed with the following composition: Components phr NeoCis 40 Butadiene Rubber 100.0 Kulite ™ Tungsten Powder (5 microns)1248.5 Iron Powder 100.0 Zinc Oxide 5.0 Varox ™ 231XL Peroxide Initiator3.0 Zinc Diacrylate 0.0 TOTAL 1456.5

[0259] The spherical center core layer comprising the above compositionexhibited a specific gravity of 7.65, a weight of 2.7 grams, and a ShoreC hardness of 80 (preferred range is 50-95).

[0260] The iron powder of the above composition was optional and wasadded to the composition in order to attract the formed center to amagnet. Such attraction allows for automated assembly of the 0.344 inchspherical center to the uncured preformed half shells in golf ballproduction.

[0261] As mentioned above, zinc diacrylate (ZDA) is not included in thecomposition of the center core layer of the present invention. Zincdiacrylate is normally added to core compositions in golf ballproduction in order to increase hardness.

[0262] An outer core layer was disposed about the spherical center corelayer presented above. The outer core layer had the followingcomposition: Components phr BCP-820 40 Neo Cis 40 30 Neo Cis 60 30 ZincOxide 13.7 Zinc Stearate 16 Zinc Diacrylate 21.3 Trigonox 42-40 Peroxide1.25 Total 152.25

[0263] The molded dual core comprising a spherical center and outer corelayer with the above compositions exhibited the following properties:Molded Dual Core Properties Size (inches) 1.478 (37.5 mm) Weight (grams)32.83 Riehle Compression 140 (.140 inches of deformation) C.O.R. 0.768Specific Gravity 1.10

[0264] A centerless ground dual core comprising a spherical center andouter core layer with the above compositions exhibited the followingproperties: Centerless Ground Dual Core Properties Size (inches) 1.469(37.3 mm) Weight (grams) 32.24 Riehle Compression 137 (.137 inches)C.O.R. 0.774 Specific Gravity 1.18

[0265] In forming a multi-layered golf ball comprising the dual corehaving a spherical center core layer and an outer core layer with theabove compositions, the following inner cover layer, i.e., mantle layer,composition was used: Inner Cover (Mantle) Layer Composition Componentsphr lotek 1002 50 lotek 1003 50 Total 100

[0266] Upon the formation of the inner cover layer on the dual core toform an intermediate ball, the combination of an inner cover layer anddual core exhibited the following properties: Combination of Inner CoverLayer and Dual Core Properties Size (inches) 1.570 Weight (grams) 38.3Riehle Compression 113 (.113 inches) C.O.R. 0.803 Shore D 68-72 SpecificGravity 1.15

[0267] An outer cover layer was disposed about the inner cover layerhaving the following formulation: Outer Cover Layer CompositionComponents Parts by Weight lotek 7510 41 lotek 7520 49.5 White M. B.¹(Master Batch) 9.5

[0268] The molded balls may optionally be subjected to gamma radiationtreatment at about 40 kilograys to crosslink the cover to improve scuffand cut resistance. The gamma radiation also increases the crosslinkdensity of the core and results in a harder core and ball compression.Below is a comparison of properties exhibited by a golf ball prior togamma radiation and properties exhibited by a golf ball subjected togamma radiation: Dual Core, Multi-Layered, Golf Ball Properties RiehleGolf Ball Size (inches) Weight (grams) Compression C.O.R. Molded Ball1.685 45.2 104 0.789 Before Gamma (.104 inches) Radiation Molded Ball1.683 45.2  87 0.805 After Gamma (.087 inches) Radiation Finished Golf1.684 45.3  87 0.805 Ball (.087 inches)

[0269] 1 B. A Dual Core and Single Layer Golf Ball

[0270] A spherical center core layer having a diameter of 0.344 incheswas formed with the following composition: Components phr Neo Cis 40Butadiene Rubber 100.0 Kulite Tungsten Powder (5 microns) 1248.5 IronPowder 100.0 Zinc Oxide 5.0 Varox 231XL Peroxide 3.0 Zinc Diacrylate 0.0TOTAL 1456.5

[0271] The spherical center comprising the above composition exhibited aspecific gravity of 7.65, a weight of 2.7 grams, and a Shore C hardnessof 80.

[0272] Again, the iron powder of the above composition was againoptional and was added to the composition in order to attract thecomposition to a magnet. As mentioned above, such attraction allows forautomated assembly of the 0.344 inch spherical center to the uncuredpreformed half shells in golf ball production.

[0273] An outer core layer was disposed about the spherical centerhaving the following composition: Components phr BCP-820 40 Neo Cis 4030 Neo Cis 60 30 Zinc Oxide 9.5 Zinc Stearate 16 Zinc Diacrylate 29Trignonox 42-40 Peroxide 1.25 Total 155.75

[0274] The molded dual core comprising a spherical center core layer andan outer core layer with the above compositions exhibited the followingproperties: Molded Dual Core Properties (with 11/32″ Heavy WeightSpherical Center) Size (inches) 1.559 Weight (grams) 38.1 RiehleCompression 94 (0.094″) C.O.R. 0.799 Specific Gravity 1.11

[0275] A single layer cover was disposed about the dual core having thefollowing composition: Cover Layer Composition Components Parts byWeight lotek 7510 41 lotek 7520 49.5 White M.B.¹ 9.5 Total 100

[0276] Once again, the molded balls may optionally be subjected to gammaradiation treatment at about 40 kilograys to crosslink the cover toimprove scuff and cut resistance. The gamma radiation also increases thecrosslink density of the core and results in a harder core and ballcompression. Below is a comparison of properties exhibited by a golfball prior to gamma radiation and properties exhibited by a golf ballsubjected to gamma radiation: Dual Core, Single-Layered Golf BallProperties Riehle Golf Ball Size (inches) Weight (grams) CompressionC.O.R. Molded Ball 1.684 45.8 96 0.792 Before Gamma (.096 inches)Radiation Molded Ball 1.681 45.8 77 0.814 After Gamma (.077 inches)Radiation Finished Golf 1.682 45.9 76 0.816 Ball (.076 inches)

Example 2

[0277] Spin rate testing was conducted with the finished multi-layeredcovered, dual core golf balls (Example 1A) and single-layered cover,dual core golf balls (Example 1B) of above Example using a driver, a 5iron, a 9 iron, and a pitching wedge. The golf ball testing machine wasset up to emulate the launch conditions of an average TouringProfessional Golfer for each particular club. For comparative purposes,commercial golf balls were also tested for spin rate using the sameclubs.

[0278] Below are the results of the spin rate testing: Spin Rate Datafor Examples 1A (Dual Core, Dual Cover) and 1B (Dual Core, Single Cover)Spin Ball Launch Rate Velocity Club Ball Type Angle (rpm) (ft./sec.)10.5 Example 1A 10.9 3806 229.5 Intimidator ™ Example 1B 10.3 3072 231.1Driver Strata ™ 10.7 2896 227.4 Professional 90 Precept ™ MC Spin 11.12888 226.5 Titleist ™ Prestige 90 11.0 3074 227.7 5 Iron Example 1A 15.75798 184.5 Apex Plus ™ Example 1B 15.0 7347 182.2 Strata ™ 15.8 5713182.5 Professional 90 Precept ™ MC Spin 15.8 5445 183.1 Titleist ™Prestige 90 15.2 5840 181.3 9 Iron Example 1A 24.0 8668 145.2 ApexPlus ™ Example 1B 21.9 10607 143.3 Strata ™ 24.1 8713 145.4 Professional90 Precept ™ MC Spin 23.9 8579 144.7 Titleist ™ Prestige 90 24.1 8395143.7 Pitching Example 1A 29.0 10571 132.9 Wedge Example 1B 27.0 12654133.5 Apex Strata ™ Professional 90 27.6 10467 133.6 Plus ™ Precept ™ MCSpin 28.2 10656 132.5 Titleist ™ Prestige 90 29.2 10105 130.0

[0279] The above results indicate that the solid, non-wound golf ballshaving a heavy elastomeric center exhibit enhanced overall high spinproperties.

Example 3

[0280] One half of the polybutadiene rubber utilized in the inner coreof Examples 1-2 was deleted and substituted with polyisoprene.Specifically, 50 phr of Natsyn 2000 was substituted for Neo-Cis 40according to the following formula: ACTUAL MATERIAL PHR Sp.Gr. EnichemNeo Cis 40 50.00 0.910 Goodyear Natsyn 2200 50.00 0.910 Kulite TungstenPowder 1386.40 19.350 (5 microns) Aldrich Iron Oxide, Fe₃O₄ 64.90 5.100(less than 5 microns) Zinc Oxide 5.00 5.570 Varox 231 XL Peroxide 7.501.410 TOTALS 1563.80 7.800

[0281] Inner cores having the following properties were produced:Specifications: size: 0.340 inches, ″0.006 inches weight: 2.77 grams,″0.1 grams hardness: 62 Shore C peak ″5 points

[0282] The inner cores, when enclosed with the above outer core andcover formulations, produced golf balls exhibiting the enhancedcharacteristics of the balls of Example 1.

Example 4

[0283] The inner cores produced in Example 3 above, were furtherencapsulated by several different types of outer core, inner cover(mantle) and outer cover materials at different sizes and thicknesses inorder to produce several types of alternative 2×2 constructions. In thisregard, the following finished or molded dual cores (inner core layerencompassed by the outer core layer) were produced: A) “A” Cores 1.500″2 × 2 Core with a Riehle Compression of 120-125 ACTUAL Outer Core LayerMaterial PHR Sp. Gr. BCP-820 40.00 0.910 Neo-Cis 60 30.00 0.910 Neo-Cis40 30.00 0.910 Zinc Oxide 13.10 5.570 Zn Stearate 16.00 1.090 ZDA 21.752.100 Red MB 0.10 1.500 Trigonox 42-40b Peroxide 1.25 1.400 TOTALS152.20 1.101 Molded Dual Core Properties Target Compression = 120-125Chilled Compression = 125-130 Compound S.G. = 1.1010 Molded Core Size(in) = 1.545 Target S.G. = 1.1010 Molded Volume (cc) = 31.644 BatchFactor = 29.000 Molded Core Wt. (g) = 34.84 Vol. Occupied = 4008.9 FinalTarget Size (in) = 1.500 Polymer Volume = 79.49% Core Volume (cc) =28.958 Slug Weight (″ .5 grams) = .18 Final Core Weight (g) = 34.265Center Weight = 2.7729 Outer Core Vol. (cc) = 28.603 Center Size =0.3460 Outer Core Wt. (g) = 31.492 Center Specific Gravity = 7.802Center Volume = 0.36 B) “B” Cores 1.510″ 2 × 2 Core with a RiehleCompression of 115-120 ACTUAL Material PHR Sp. Gr. BCP-820 40.00 0.910Neo-Cis 60 30.00 0.910 Neo-Cis 40 30.00 0.910 Zinc Oxide 11.58 5.570 ZnStearate 16.00 1.090 ZDA 23.50 2.100 Orange MB 0.10 1.500 Trigonox42-40b Peroxide 1.25 1.400 TOTALS 152.43 1.098 Molded Dual CoreProperties Target Compression = 115-120 Chilled Compression = 120-125Compound S.G. = 1.0982 Molded Core Size (in) = 1.545 Target S.G. =1.0980 Molded Volume (cc) = 31.644 Batch Factor = 29.000 Molded Core Wt.(g) = 34.75 Vol. Occupied = 4025.1 Final Target Size (in) = 1.510Polymer Volume = 79.17% Core Volume (cc) = 29.541 Slug Weight (″ .5grams) = .18 Final Core Weight (g) = 34.825 Center Weight = 2.7729 OuterCore Vol. (cc) = 29.186 Center Size = 0.3460 Outer Core Wt. (g) =32.052Center Specific Gravity = 7.802 C.O.R. = .7812 Center Volume = 0.36 C)“C” Cor s 1.540″ 2 × 2 Core with a Riehle Compression of 120-125 ACTUALMaterial PHR Sp. Gr. BCP-820 40.00 0.910 Neo-Cis 60 30.00 0.910 Neo-Cis40 30.00 0.910 Zinc Oxide 10.80 5.570 Zn Stearate 16.00 1.090 ZDA 22.502.100 Green MB 0.10 1.500 Trigonox 42-406 Peroxide 1.25 1.400 TOTALS150.65 1.090 Molded Dual Core Properties Target Compression = 120-125Chilled Compression = 125-130 Compound S.G. = 1.0902 Molded Core Size(in) = 1.584 Target S.G. = 1.0900 Molded Volume (cc) = 34.101 BatchFactor = 29.000 Molded Core Wt. (g) = 37.18 Vol. Occupied = 4007.3 FinalTarget Size (in) = 1.540 Polymer Volume = 79.53% Core Volume (cc) =31.338 Slug Weight (″ .5 grams) = 19 Final Core Weight (g) = 36.550Center Weight = 2.7729 Outer Core Vol. (cc) = 30.982 Center Size =0.3460 Outer Core Wt. (g) = 33.777 Center Specific Gravity = 7.802Center Volume = 0.36 D) “D” Cores - 1.470″-1.480″ 2 × 2 Core ACTUALMaterial PHR Sp. Gr. BCP-820 40.00 0.910 Neo-Cis 60 30.00 0.910 Neo-Cis40 30.00 0.910 Zinc Oxide 15.60 5.570 Zn Stearate 16.00 1.090 ZDA 20.752.100 Color MB 0.10 1.500 Trigonox 42-40b Peroxide 1.25 1.400 TOTALS153.70 1.112 Molded Dual Core Properties Target Compression = 137 TargetS.G. = 1.1120 (.137 inches) Compound S.G. = 1.1121 Polymer Volume =79.51% Batch Factor = 29.000 Target Size = 1.48 inches Vol. Occupied =4007.3 Core Volume (cc) = 27.815

[0284] The above dual cores were molded with inner cover (mantle) andouter cover materials of various thicknesses to produce the followingalternative embodiments of the invention. Core Type Mantle (Inner Cover)Outer-Cover Dot Code Size Weight Sample 1 (1.500″) 8140/9150 @ 50:50(.035″) STP¹ (.055″) 1 Black 1.684 45.56 Sample 2 (1.510″)8140/9150/6120 @ 50:25:25 STP (.045″) 1 Red 1.685 45.56 (.040″) Sample 3(1.540″) 8140/9150 @ 50:50 (.035″) STP (.035″) 1 Orange 1.692 46.24Sample 4 (1.470″) 1002/1003 @ 50:50 (.050″) STP (.055″) 1 Yellow 1.68445.55 Sample 5 (1.470″) 1002/1003 @ (.050″) (50/50) 7520/6320 1 Blue1.685 45.50 w/HCMB Sample 6 (1.480″) 8140/9150 @ 50:50 (.045″) (50/50)7520/6320 2 Orange 1.684 45.55 w/HCMB Sample 7 Strata ProductionProduction STP Stamp N/A N/A Tour Pro² Core Type Riehle (inches) C.O.R.NesFactor⁴ High Speed Rank M.O.I. Sample 1 (1.500″) .082 0.804 .886 LessComparable 0.42347 Sample 2 (1.510″) .077 0.809 .886 Comparable 0.42293Sample 3 (1.540″) .081 0.8124 .893 Comparable 0.43644 Sample 4 (1.470″).083 0.7978 .881 Comparable 0.41993 Sample 5 (1.470″) .083 0.798 .881Best 0.41979 Sample 6 (1.480″) .084 0.7971 .881 Comparable 0.42058Sample 7 Strata Tour Pro² .080 N/A N/A N/A 0.43770 Dot Code DescriptionDriver Spin 5 Iron Spin 9 Iron Spin Chip Shot Spin 1 Black 8140/9150 @50:50 (.035″) 3277 6688 9682 4230 1 Red 8140/9150/6120 @ 50:25:25 NotTested Not Tested Not Tested 4221 (.040″) 1 Orange 8140/9150 @ 50:50(.035″) 2979 6184 9267 4129 1 Yellow 1002/1003 @ 50:50 (.050″) 3121 62579456 4226 1 Blue 1002/1003 @ (.050″) 3023 6116 9224 4132 2 Orange8140/9150 @ 50:50 (.045″) 2981 6134 9341 4057 Strata Tour Pro Production2879 5945 8956 4074 Production² Titleist Pro V1³ N/A Not Tested NotTested Not Tested 3990 Dot Code Driver Dist 5.1. Carry Dist. 9 IronDist. Cut Rank Scuff Rank 1 Black 260.4 172.4 N/A Comparable Comparable1 Red 263.5 171.4 N/A Comparable Comparable 1 Orange 262.5 175.5 N/AComparable Comparable 1 Yellow 262.2 172 N/A Comparable Comparable 1Blue 261.4 174.2 N/A Slightly Better Comparable 2 Orange 261.5 172.3 N/ASlightly Better Comparable Strata Tour Pro Production² 263.2 172.1 N/AComparable Comparable Titleist Pro V1³ 263.3 172.1 N/A ComparableComparable

[0285] The above results indicate that golf balls having thinner inner(mantle) and outer cover layers and larger cores exhibited optimal spinand distance characteristics. See for example, Samples 2 and 3.

Example 5

[0286] The centers or inner cores produced in Example 3 whereencapsulated by an outer core layer material substantially similar incomposition to that of the “C” cores of Example 4 to produce 1.510 inchdual cores. These dual cores were then covered by a thin inner coverlayer of 0.0425 inches in thickness and a thin outer cover layer of thesame thickness to produce a 1.68 inch golf ball. The composition of thevarious layers and their respective properties are set forth below. A)Center or Inner Core Material S.G. Parts Volume 100% Neo Cis 40 1 50.0054.95 3.20 Natsyn 2200 1 50.00 54.95 3.20 Tungsten Powder 19 1386.4071.65 88.66 Black Iron Oxide 5 64.90 12.73 4.15 Zinc Oxide 6 5.00 0.900.32 Varox 231 XL or Trig 29/40B 1 7.50 5.36 0.48 Peroxide TOTALS 7.7991563.80 200.52 100 Batch Factor = 0.03 Banbury volume = 3 TargetHardness ″ 5 = 62 Molded Core Size = 0.343 inches Target COR = N.A. CoreVolume = 0.35 cc Calc. Slab Weight = 1690.0 grams Target Core Weight =2.70 grams Target Slab Weight = ″ 10 grams Unicore Molds = N.A. B) OuterCore Layer Material S.G. Parts Volume 100% Cariflex BPC-820 0.91 40.0043.96 26.31 Neo Cis 60 0.91 30.00 32.97 19.73 Neo Cis 40 0.91 30.0032.97 19.73 Zinc Oxide 5.57 12.25 2.20 8.06 Zinc Stearate 1.09 16.0014.68 10.52 ZDA 2.1 22.25 10.60 14.63 Orange MB 1.5 0.30 0.20 0.20 Trig42-40B Peroxide 1.4 1.25 0.89 0.82 TOTALS 1.098 152.05 138.46 100 BatchFactor = 3.37 Banbury volume = 450 Target Compression = 122 Molded CoreSize = 1.525 inches Target COR = 0.775 Core Volume = 31.68 cc Calc. SlugWeight = 16.0 grams Target Core Weight = 34.79 grams Target Slug Weight= 17.5 grams Unicore Molds = .29 2 slugs per core C) Inner Cover LayersAccumulative Weight Materials Weight (Pounds) Tare Scale to 0 LBS.Weight % Surlyn 6120 45.0 45.0 25.0 Surlyn 8140 90.0 135.0 50.0 Surlyn9150 45.0 180.0 25.0 D) Outer Cover Layers Materials Weight (Pounds)Accumulative Weight Weight % White M.B. 17.1 17.1 9.5 lotek 7510 73.8164.7 41.0 lotek 7520 89.1 180.0 49.5

[0287] The materials and components produced a regulation size golf ballwith a large core and thin cover layers having the followingcharacteristics: Center or Inner Core Layer Formula “A” Above Size In. 0.340 Wgt. Grams  2.77 Shore C 62 Outer Core Layer Formula “B” AboveSize In.  1.51 Wgt. Grams 34.8 Comp. Riehle  0.122 inches C.O.R.  0.775Inner Cover Layer Cover Formula “C” Above Size In.  1.59 Wgt. Grams 39.4Comp. Riehle  0.102 inches C.O.R.  0.800 Mantle Thickness (In.)  0.0425Outer Cover Layer (Pre-Gamma Treatment) Cover Formula “D” Above Size In. 1.684 Wgt. Grams 45.3 Comp. Riehle  0.100 inches C.O.R.  0.792 CoverThickness (In.)  0.0425 Finished Ball (Post-Gamma Treatment) Size In. 1.682 Wgt. Grams 45.4 Comp. Riehle  0.080 inches C.O.R.  0.805 CoverThickness (In.)  0.0425 Shore D 47

Example 6

[0288] An additional relative thin covered embodiment of the presentinvention was produced using the same center and outer cover materialsset forth in Example 5. However, in this embodiment, slightly alteredouter core layer and inner cover layer materials were utilized.Moreover, the size and the thicknesses of the components differedsomewhat. The materials and properties of the different layers in thisrelatively thin covered embodiment of the inventions are set forthbelow. A) Center or Inner Core ACTUAL Outer Care Layer Material PHRSp.Gr. BCP-820 40.00 0.910 Neo-Cis 60 30.00 0.910 Neo-Cis 40 30.00 0.910Zinc Oxide 13.10 5.570 Zn Stearate 16.00 1.090 ZDA 21.75 2.100 Red M.B.0.10 1.500 Trigonox 42-40b Peroxide 1.25 1.400 TOTALS 152.20 1.101Molded Dual Core Properties Target Compression = 137 Targ t S.G. =1.1120 Compound S.G. = 1.1121 Polymer Volume = 79.51% Batch Factor =29.000 Target Size = 1.48 Vol. Occupied = 4007.3 Car Volum (cc) = 27.815B) Outer Core Layer ACTUAL Outer Core Layer Material PHR Sp.Gr. Vol.Vol. % BCP-820 40.00 0.910 43.956 31.85 Neo-Cis 60 30.00 0.910 32.96723.89 Neo-Cis 40 30.00 0.910 32.967 23.89 Zinc Oxide 15.88 5.570 2.8512.07 Zn Stearate 16.00 1.090 14.679 10.64 ZDA 20.25 2.100 9.643 6.99Violet M.B. 0.10 1.500 0.067 0.05 Trigonox 42-40b Peroxide 1.25 1.4000.893 0.65 TOTALS 153.48 1.112 138.02 100.00 Compound S.G. = 1.1120Target S.G. = 1.1120 Polymer Vol. = 79.62% C) Inner Cover Layer WEIGHTACCUMULATIVE WGT. MATERIALS (POUNDS) TARE SCALE TO 0 LBS. lotek EX1002/5031/8420 90.0 90.0 lotek EX 1003/5041/7410 90.0 90.0 D) OuterCover Layer Materials Weight (Pounds) Accumulative Weight Weight % WhiteM.B. 17.1 17.1 9.5 lotek 7510 73.8 164.7 41.0 lotek 7520 89.1 180.0 49.5

[0289] The materials and components produced a regulation size golf ballwith a relatively large core and thin cover layers having the followingcharacteristics: Center or Inner Core Layer Formula “A” Above Size In. 0.340 Wgt. Grams  2.77 Shore C 62 Outer Core Layer Formula “B” AboveSize In.  1.47 Wgt. Grams 32.45 Comp. Riehle  0.137 (inches) C.O.R. 0.767 Inner Cover Layer Cover Formula “C” Above Size In.  1.57 Wgt.Grams 38.3 Comp. Riehle  0.118 (inches) C.O.R.  0.800 Mantle Thickness(In.)  0.050 Outer Cover Layer Cover Formula “D” Above (Pre-GammaTreatment) Size In.  1.684 Wgt. Grams 45.3 Comp. Riehle  0.104 (inches)C.O.R.  0.788 Cover Thickness (In.)  0.055 Finished Ball Size In.  1.682(Post-Gamma Treatment) Wgt. Grams 45.4 Comp. Riehle  0.085 (inches)C.O.R.  0.798 Cover Thickness (In.)  0.055

[0290] The invention has been described with reference to the preferredembodiments. Obviously, modifications and alterations will occur toothers upon a reading and understanding the preceding detaileddescription. It is intended that the invention be construed as includingall such modifications and alterations in so far as they come within thescope of the appended claims or the equivalents thereof.

What is claimed:
 1. A solid golf ball comprising: a dual core includingan inner, high density, spherical center core layer and an outer corelayer disposed about said spherical center core layer, wherein saidspherical center core layer has a specific gravity from about 4.0 toabout 20.0, a diameter of about 0.200 inches to about 0.830 inches, anda Shore C hardness of 95 or less and comprises a blend including apowdered metal and a first matrix material comprising a thermosetelastomeric base material, and wherein said outer core layer has aspecific gravity of less than 1.2, a diameter of from about 1.25 to 1.60inches, and comprises a second matrix material selected from the groupconsisting of thermosets, thermoplastics, and combinations thereof; aninner cover layer formed about said dual core having a thickness ofabout 0.010 inches to about 0.055 inches wherein said inner cover layerhas a Shore D hardness of 58 or more; and an outer cover layer disposedon said inner cover layer having a thickness of about 0.010 inches toabout 0.055 inches, wherein said outer cover layer has a Shore Dhardness less than the Shore D hardness of the inner cover layer.
 2. Agolf ball according to claim 1, wherein the difference in Shore Dhardnesses between the inner cover and the outer cover is 8 or more. 3.A golf ball according to claim 1, wherein said outer cover layer has aShore D hardness of 50 or less.
 4. A golf ball according to claim 1,wherein the difference in Shore D hardnesses between the inner cover andthe outer cover is 11 or more.
 5. A golf ball according to claim 1,wherein said outer cover layer has a Shore D hardness of 47 or less. 6.A golf ball according to claim 1, wherein at least one of said coverlayers has a thickness of 0.040 inches or less.
 7. A golf ball accordingto claim 1, wherein at least one of said cover layers has a thickness of0.035 inches or less.
 8. A golf ball according to claim 1, wherein saiddual core has a specific gravity of about 1.10 to about 1.18.
 9. A golfball according to claim 1, wherein the spherical center core layer has aShore D hardness of from 50 to
 95. 10. A golf ball according to claim 1,wherein the spherical center core layer has a Shore C hardness of about80.
 11. A golf ball according to claim 1, wherein the specific gravityof the spherical center core layer differs from that of the outer corelayer by more than 2.0.
 12. A golf ball according to claim 1, whereinthe Shore C hardness of the inner core layer is less than the Shore Chardness of the outer core layer.
 13. A golf ball according to claim 1,wherein said golf ball exhibits a moment of inertia of less than 0.43oz.in².
 14. A solid golf ball comprising: a dual core including aninner, high density, spherical center and outer core layer disposedabout said spherical center, wherein said spherical center has aspecific gravity of 2.0 or more, and a Shore C hardness of 50 to 95, andcomprises a blend including a powdered metal and a first matrix materialcomprising a thermoset elastomeric base material and wherein said outercore layer comprises a second matrix material selected from the groupconsisting of thermosets, thermoplastics, 45 and combinations thereof,wherein said outer core layer has a specific gravity of from about 0.09to about 1.2 and a diameter of from about 1.47 to 1.595 inches; an innercover layer formed about said dual core having a thickness of about0.020 inches to about 0.050 inches' and a Shore D hardness of 68 ormore; and an outer cover layer disposed on said inner cover layer havinga thickness of about 0.020 to about 0.050 inches and a Shore D hardnessof 50 or less.
 15. A golf ball according to claim 14, wherein at leastone of the cover layers comprises an ionomer resin, a polyurethane, orblends thereof.
 16. A golf ball according to claim 14, wherein saidinner cover layer comprises at least in part an ionomer resin having anacid content greater than 16 weight percent.
 17. A golf ball accordingto claim 14, wherein said powdered metal comprises tungsten powder. 18.A golf ball according to claim 14, wherein said second matrix materialof said outer core layer is selected from the group consisting of apolybutadiene, a polyisoprene, an ionomer resin, or combinationsthereof.
 19. A golf ball according to claim 14, wherein said sphericalcenter has a diameter of from about 0.200 inches to about 0.830 inches.20. A golf ball according to claim 14, wherein said spherical center hasa diameter of about 0.200 inches to about 0.600 inches.
 21. A golf ballaccording to claim 14, wherein said powdered metal is dispersedthroughout said first matrix material of said spherical center.
 22. Agolf ball according to claim 14, wherein the difference between thespecific gravity of said spherical center and said outer core layer isgreater than 2.0.
 23. A golf ball according to claim 14, wherein thespherical center core layer is lower in Shore C hardness than the outercore layer.
 24. A golf ball according to claim 14, wherein said innercover is an ionomer resin and said outer cover is a thermoplasticpolyurethane
 25. A golf ball according to claim 14, wherein saidspherical center exhibits a specific gravity of 2.0 to 18.0.
 26. A golfball according to claim 14, wherein said powdered metal constitutes atleast 50% by weight of said spherical center.
 27. A golf ball accordingto claim 14, wherein said powdered metal is selected from the groupconsisting of tungsten powder and iron powder and combinations thereof.28. A solid, non-wound, golf ball comprising: a dual core including aninner, high density, spherical center core layer and an outer core layerdisposed about said spherical center core layer, wherein said sphericalcenter core layer has a specific gravity greater than 1.2 and a diameterof about 0.200 inches to about 0.830 inches and a diameter of from about1.25 to 1.60 inches; an inner ionomeric cover layer formed about saiddual core having a thickness of less than 0.045 inches and a Shore Dhardness of 68 or more; and an outer ionomeric cover layer disposed onsaid inner cover layer having a thickness of less than 0.045 inches anda Shore D hardness of 50 or less.
 29. A golf ball according to claim 28,wherein the difference in Shore D hardnesses between the inner cover andthe outer cover is 8 or more.
 30. A golf ball according to claim 28,wherein at least one of said cover layers has a thickness of 0.040inches or less.
 31. A golf ball according to claim 28, wherein at leastone of said cover layers has a thickness of 0.035 inches or less.
 32. Agolf ball according to claim 28, wherein said dual core has a specificgravity of about 1.10 to about 1.18.
 33. A golf ball according to claim28, wherein the spherical center core layer has a Shore D hardness offrom 50 to
 95. 34. A golf ball according to claim 28, wherein thespecific gravity of the spherical center core layer differs from that ofthe outer core layer by more than 2.0.
 35. A golf ball according toclaim 28, wherein the Shore C hardness of the inner core layer is lessthan the Shore C hardness of the outer core layer.
 36. A golf ballaccording to claim 28, wherein said golf ball exhibits a moment ofinertia of less than 0.43 oz.in².